SMART 500 ADVANCED GENSET CONTROLLER COMMUNICATIONS DESCRIPTION TOPOLOGIES FUNCTIONALITIES

Transcription

1 SMART 500 ADVANCED GENSET CONTROLLER DESCRIPTION The D-xxx series are next generation genset control units combining multi-functionality and wide communication possibilities together with a reliable and low cost design. The unit complies and mostly exceeds world s tightest safety, EMC, vibration and environmental standards for the industrial category. Software features are complete with easy firmware upgrade process through USB port. The Windows based PC software allows monitoring and programming through USB, serial and GPRS. The PC based Rainbow Scada software allows monitoring and control of an unlimited number of gensets from a single central location. FUNCTIONALITIES AMF unit with uninterrupted transfer ATS unit with uninterrupted transfer Remote start controller Manual start controller Engine controller Remote display & control unit Waveform display of V & I Harmonic analysis of V & I CTs at genset or load side COMMUNICATIONS GSM-GPRS Internal GPRS modem (optional) GSM-SMS Modbus USB Device RS-485 RS-232 J1939-CANBUS TOPOLOGIES 3 phases 4 wires, star 3 phases 3 wires, 3 CTs 3 phases 3 wires, 2 CTs (L1-L2) 3 phases 3 wires, 2 CTs (L1-L3) 2 phases 3 wires, L1-L2 2 phases 3 wires, L1-L3 3 phases 4 wires, delta 1 phase 2 wires

2 COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part of this document is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. ABOUT THIS DOCUMENT This document describes minimum requirements and necessary steps for the successful installation of the D-xxx family units. Follow carefully advices given in the document. These are often good practices for the installation of genset control units which reduce future issues. For all technical queries please contact EMSA at below address: QUERRIES If additional information to this manual is required, please contact the manufacturer directly at below e- mail address: Please provide following information in order to get answers to any question: - Device model name (see the back panel of the unit), - Complete serial number (see the back panel of the unit), - Firmware version (read from the display screen), - Measuring-circuit voltage and power supply voltage, - Precise description of the query. RELATED DOCUMENTS FILENAME DESCRIPTION 500-Rainbow Installation 500-Rainbow Usage Rainbow Plus D-500 D-700 Installation Guide Rainbow Plus D-500 D-700 Usage Guide 500-GSM Configuration GSM Configuration Guide for D-500 D Firmware Update Firmware Update Guide for D-500 D MODBUS Modbus Application Manual for D-500 D Rainbow Scada Installation Rainbow Scada Installation Guide 500-Rainbow Scada Usage Rainbow Scada Usage Guide L11D03-EN - 2 -

3 REVISION HISTORY REVISION DATE AUTHOR DESCRIPTION MH First edition, firmware version 5.4 TERMINOLOGY CAUTION: Potential risk of injury or death. WARNING: Potential risk of malfunction or material damage. ATTENTION: Useful hints for the understanding of device operation. L11D03-EN - 3 -

4 ORDERING CODES The family units are available in various options and peripheral features. Please use below information for ordering the correct version: S500 -M -G -T -00 Family Code Variant 00: standard unit : customer specific products With Internal GSM-GPRS With Sealing gasket With Conformal Coating SPARE PARTS Screw type bracket Stock Code=J10P01 (per unit) Self Retaining type bracket Stock Code=K16P01 (per unit) Sealing Gasket L11D03-EN - 4 -

5 SAFETY NOTICE Failure to follow below instructions will result in death or serious injury Electrical equipment should be installed only by qualified specialist. No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences resulting from the non-compliance to these instructions. Check the unit for cracks and damages due to transportation. Do not install damaged equipment. Do not open the unit. There are no serviceable parts inside. Fuses must be connected to the power supply and phase voltage inputs, in close proximity of the unit. Fuses must be of fast type (FF) with a maximum rating of 6A. Disconnect all power before working on equipment. When the unit is connected to the network do not touch terminals. Short circuit terminals of unused current transformers. Any electrical parameter applied to the device must be in the range specified in the user manual. Although the unit is designed with a wide safety margin, over-range parameters may reduce lifetime, alter operational precision or even damage the unit. Do not try to clean the device with solvent or the like. Only clean with a dump cloth. Verify correct terminal connections before applying power. Only for front panel mounting. Current Transformers must be used for current measurement. No direct connection allowed. L11D03-EN - 5 -

6 TABLE OF CONTENTS 1. INSTALLATION INSTRUCTIONS 2. MOUNTING 2.1 DIMENSIONS 2.2 SEALING, GASKET 2.3 ELECTRICAL INSTALLATION 3. TERMINAL DESCRIPTIONS 3.1. BATTERY VOLTAGE INPUT 3.2. AC VOLTAGE INPUTS 3.3. AC CURRENT INPUTS 3.4. DIGITAL INPUTS 3.5. ANALOG SENDER INPUTS AND SENDER GROUND 3.6. CHARGE INPUT TERMINAL 3.7. MAGNETIC PICKUP INPUT 3.8. MAINS CONTACTOR OUTPUT 3.9. GENERATOR CONTACTOR OUTPUT DIGITAL OUTPUTS INPUT/OUTPUT EXTENSION RS-485 PORT RS-232 PORT J1939-CANBUS PORT USB DEVICE PORT GSM MODEM (OPTIONAL) 4. TOPOLOGIES 4.1. SELECTING THE TOPOLOGY PHASE, 4 WIRE, STAR PHASE, 3 WIRE, DELTA PHASE, 4 WIRE, DELTA PHASE, 3 WIRE, DELTA, 2 CT (L1-L2) PHASE, 3 WIRE, DELTA, 2 CT (L1-L3) PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2) PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3) PHASE, 2 WIRE L11D03-EN - 6 -

7 5. FUNCTIONALITIES 5.1. CT LOCATION SELECTION 5.2. AMF FUNCTIONALITY 5.3. ATS FUNCTIONALITY 5.4. REMOTE START FUNCTIONALITY 5.5 ENGINE CONTROLLER FUNCTIONALITY 5.6. REMOTE DISPLAY UNIT FUNCTIONALITY HZ OPERATION 6. CONNECTION DIAGRAMS 6.1. AMF FUNCTIONALITY, CTs AT LOAD SIDE 6.2. AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE 6.3. ATS FUNCTIONALITY 6.4. REMOTE START FUNCTIONALITY 6.5. ENGINE CONTROL FUNCTIONALITY 6.6. REMOTE DISPLAY PANEL FUNCTIONALITY 7. TERMINAL DESCRIPTION 8. TECHNICAL SPECIFICATIONS 9. DESCRIPTION OF CONTROLS 9.1. FRONT PANEL FUNCTIONALITY 9.2. PUSHBUTTON FUNCTIONS 9.3. DISPLAY SCREEN ORGANIZATION 9.4. AUTOMATIC DISPLAY SCROLL 9.5. MEASURED PARAMETERS 9.6. LED LAMPS 10. WAVEFORM DISPLAY & HARMONIC ANALYSIS 11. DISPLAYING EVENT LOGS 12. STATISTICAL COUNTERS FUEL FILLING COUNTER FUEL CONSUMPTION MONITORING 13. OPERATION OF THE UNIT QUICK START GUIDE STOP MODE AUTO MODE RUN MODE, MANUAL CONTROL TEST MODE 14. PROTECTIONS AND ALARMS DISABLING ALL PROTECTIONS SERVICE REQUEST ALARM SHUTDOWN ALARMS LOADDUMP ALARMS L11D03-EN - 7 -

8 14.5. WARNINGS NON-VISUAL WARNINGS 15. PROGRAMMING RESETTING TO FACTORY DEFAULTS ENTERING THE PROGRAMMING MODE NAVIGATING BETWEEN MENUS MODIFYING PARAMETER VALUE PROGRAMMING MODE EXIT 16. PROGRAM PARAMETER LIST CONTROLLER CONFIGURATION GROUP ELECTRICAL PARAMETERS GROUP ENGINE PARAMETERS GROUP ADJUST DATE AND TIME WEEKLY OPERATION SCHEDULE EXERCISER SCHEDULE SENDER CONFIGURATION DIGITAL INPUT CONFIGURATION OUTPUT CONFIGURATION SITE ID STRING ENGINE SERIAL NUMBER MODEM1-2/SMS TELEPHONE NUMBERS GSM MODEM PARAMETERS ETHERNET PARAMETERS 17. CRANK CUTTING 18. OVERCURRENT PROTECTION (IDMT) 19. MOTORIZED CIRCUIT BREAKER CONTROL 20. J1939 CANBUS ENGINE SUPPORT 21. GPS SUPPORT 22. GSM CONFIGURATION 23. CENTRAL MONITORING OF GENSETS 24. SENDING 25. SMS COMMANDS L11D03-EN - 8 -

9 26. SOFTWARE FEATURES LOAD SHEDDING / DUMMY LOAD LOAD ADD / SUBSTRACT FIVE STEP LOAD MANAGEMENT REMOTE START OPERATION DISABLE AUTO START, SIMULATE MAINS BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS DUAL GENSET MUTUAL STANDBY OPERATION MULTIPLE VOLTAGE AND FREQUENCY SINGLE PHASE OPERATION EXTERNAL CONTROL OF THE UNIT AUTOMATIC EXERCISER WEEKLY OPERATION SCHEDULER ENGINE HEATING OPERATION ENGİNE IDLE SPEED OPERATİON ENGINE BLOCK HEATER FUEL PUMP CONTROL GAS ENGINE FUEL SOLENOID CONTROL PRE-TRANSFER SIGNAL CHARGING THE ENGINE BATTERY EXTERNALLY CONTROLLED DIGITAL OUTPUTS COMBAT MODE RESETTING THE CONTROLLER AUTOMATIC CONNECTION TOPOLOGY DETERMINATION ZERO POWER AT REST 27. MODBUS COMMUNICATIONS PARAMETERS REQUIRED FOR RS-485 MODBUS OPERATION DATA FORMATS 28. DECLARATION OF CONFORMITY 29. MAINTENANCE 30. DISPOSAL OF THE UNIT 31. ROHS COMPLIANCE 32. TROUBLESHOOTING GUIDE L11D03-EN - 9 -

10 1. INSTALLATION INSTRUCTIONS Before installation: Read the user manual carefully, determine the correct connection diagram. Remove all connectors and mounting brackets from the unit, then pass the unit through the mounting opening. Put mounting brackets and tighten. Do not tighten too much, this can brake the enclosure. Make electrical connections with plugs removed from sockets, then place plugs to their sockets. Be sure that adequate cooling is provided. Be sure that the temperature of the environment will not exceed the maximum operating temperature in any case. Below conditions may damage the device: Incorrect connections. Incorrect power supply voltage. Voltage at measuring terminals beyond specified range. Voltage applied to digital inputs over specified range. Current at measuring terminals beyond specified range. Overload or short circuit at relay outputs Connecting or removing data terminals when the unit is powered-up. High voltage applied to communication ports. Ground potential differences at non-isolated communication ports. Excessive vibration, direct installation on vibrating parts. Current Transformers must be used for current measurement. No direct connection allowed. Below conditions may cause abnormal operation: Power supply voltage below minimum acceptable level. Power supply frequency out of specified limits Phase order of voltage inputs not correct. Current transformers not matching related phases. Current transformer polarity incorrect. Missing grounding. L11D03-EN

11 Dimensions: 200x148x47mm (7.9 x5.8 x1.9 ) Panel Cutout: 176x121mm minimum (7.0 x4.8 ) Weight: 450g (1 lb) MN-N MN-L3 MN-L2 MN-L1 MN-C I I I I I 2. MOUNTING 2.1. DIMENSIONS RS BAT + BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG SND 1 SND 2 SND 3 SGND IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 MPU+ MPU- / PGND CANH CANL PGND 485-B 485-A G-C G-L1 G-L2 G-L3 G-N I SIM CARD! 8 to 36Vdc, 500mA max 300Vac, Hz 0.2 to 6.0 Aac I/O EXTENSION GSM ANTENNA USB-DEVICE L11D03-EN

12 The unit is designed for panel mounting. The user should not be able to access parts of the unit other than the front panel. Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and connectors from the unit, then pass the unit through the mounting opening. Place and tighten mounting brackets. Panel Cutout Required Panel Depth L11D03-EN

13 Two different types of brackets are provided: Screw type bracket Self retaining type bracket Installation of screw type bracket Installation of self retaining type bracket Do not tighten too much, this may break the unit. L11D03-EN

14 2.2. SEALING, GASKET Panel Gasket Module The rubber gasket provides a watertight means of mounting the module to the genset panel. Together with the gasket, IEC IP65 protection can be reached from the front panel. A short definition of IP protection levels is given below. 1st Digit Description of Protection Level 0 Not protected 1 Protected against solid foreign objects of 50 mm diameter and greater 2 Protected against solid foreign objects of 12,5 mm diameter and greater 3 Protected against solid foreign objects of 2,5 mm diameter and greater 4 Protected against solid foreign objects of 1,0 mm diameter and greater 5 Protected from the amount of dust that would interfere with normal operation 6 Dust tight 2nd Digit Description of Protection Level 0 Not protected 1 Protected against vertically falling water drops 2 Protected against vertically falling water drops when enclosure is tilted up to 15 3 Protected against water sprayed at an angle up to 60 on either side of the vertical 4 Protected against water splashed against the component from any direction 5 Protected against water projected in jets from any direction 6 Protected against water projected in powerful jets from any direction 7 Protected against temporary immersion in water 8 Protected against continuous immersion in water, or as specified by the user L11D03-EN

15 2.3. ELECTRICAL INSTALLATION Do not install the unit close to high electromagnetic noise emitting devices like contactors, high current busbars, switchmode power supplies and the like. Although the unit is protected against electromagnetic disturbance, excessive disturbance can affect the operation, measurement precision and data communication quality. ALWAYS remove plug connectors when inserting wires with a screwdriver. Fuses must be connected to the power supply and phase voltage inputs, in close proximity of the unit. Fuses must be of fast type (FF) with a maximum rating of 6A. Use cables of appropriate temperature range. Use adequate cable section, at least 0.75mm 2 (AWG18). Follow national rules for electrical installation. Current transformers must have 5A output. For current transformer inputs, use at least 1.5mm 2 section (AWG15) cable. The current transformer cable length should not exceed 1.5 meters. If longer cable is used, increase the cable section proportionally. Current Transformers must be used for current measurement. No direct connection allowed. The engine body must be grounded. Otherwise faulty voltage and frequency measurements may occur. For the correct operation of the exerciser and weekly schedule programs, adjust the real time clock of the unit through programming menu. L11D03-EN

16 3. TERMINAL DESCRIPTIONS 3.1. BATTERY VOLTAGE INPUT Supply voltage: 8 to 36VDC Cranking dropouts: Overvoltage protection: Reverse voltage: Maximum operating current: Typical operating current: Measurement range: Display resolution: Accuracy: Survives 0VDC during 100ms. The voltage before surge should be 8VDC minimum Withstands 150VDC continuously. -33VDC continuous 12VDC. (All options included, digital outputs open.) 24VDC. (All options included, digital outputs open.) 12VDC. (all options passive, digital outputs open) 24VDC. (all options passive, digital outputs open) 0 to 36VDC 0.1VDC 0.5% VDC L11D03-EN

17 3.2. AC VOLTAGE INPUTS Measurement method: Sampling rate: Harmonic analysis: Input voltage range: Minimum voltage for frequency detection: Supported topologies: Measurement range: Common mode offset: Input impedance: Display resolution: Accuracy: True RMS 8000 Hz up to 31th harmonic 14 to 300 VAC 15 VAC (Ph-N) 3 ph 4 wires star 3 ph 3 wires delta 3ph 4 wires delta 2ph 3 wires L1-L2 2ph 3 wires L1-L3 1 ph 2 wires 0 to 330VAC ph-n (0 to 570VAC ph-ph) max 100V between neutral and BAT- 4.5M-ohms 1VDC 0.5% VAC ph-n (±2VAC ph-n) 0.5% VAC ph-ph (±3VAC ph-ph) Frequency range: Frequency display resolution: Frequency accuracy: DC to 500Hz 0.1 Hz 0.2% + 1 digit (±0.1 50Hz) L11D03-EN

18 3.3. AC CURRENT INPUTS Measurement method: Sampling rate: Harmonic analysis: Supported topologies: CT secondary rating: Measurement range: Input impedance: True RMS 8000 Hz up to 31th harmonic 3 ph 3 CTs 3 ph 2 CTs L1-L2 3 ph 2 CTs L1-L3 2 ph 2 CTs L1-L2 2 ph 2 CTs L1-L3 1 ph 1 CT 5A 5/5 to 5000/5A minimum 15 mili-ohms Burden: 0.375W Maximum continuous current: 6A Measurement range: 0.1 to 7.5A Common mode offset: Display resolution: Accuracy: Max 5VAC between BAT- and any CT terminal. 1A 0.5% + 1 5A (± 5/500A full range) SELECTING THE CT RATING AND CABLE SECTION: The load on a CT should be kept minimum in order to minimize phase shift effect of the current transformer. Phase shift in a CT will cause erroneous power and power factor readings, although amp readings are correct. Datakom advises CT rating to be selected following this table for the best measurement accuracy. SELECTING THE CT ACCURACY CLASS: The CT accuracy class should be selected in accordance with the required measurement precision. The accuracy class of the Datakom controller is 0.5%. Thus 0.5% class CTs are advised for the best result. L11D03-EN

19 Current Transformers must be used for current measurement. No direct connection allowed. No common terminals or grounding allowed. CONNECTING CTs: Be sure of connecting each CT to the related phase input with the correct polarity. Mixing CTs between phases will cause faulty power and pf readings. Many combinations of incorrect CTs connections are possible, so check both order of CTs and their polarity. Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement. CORRECT CT CONNECTIONS Let s suppose that the genset is loaded with 100 kw on each phase. The load Power Factor (PF) is 1. Measured values are as follows: kw kvar kva pf Phase L Phase L Phase L Total L11D03-EN

20 EFFECT OF POLARITY REVERSAL The generator is still loaded with 100 kw On each phase. The load Power Factor (PF) is 1. PF in phase L2 will show -1,00 due to reverse CT polarity. The result is that total generator power displayed by the controller is 100 kw. Measured values are as follows: kw kvar kva pf Phase L Phase L Phase L Total EFFECT OF PHASE SWAPPING The generator is still loaded with 100 kw on each phase. The load Power Factor (PF) is 1. PF in phases L2 and L3 will show -0,50 due to phase shift between voltages and currents which is caused by CT swapping. The result is that total generator power displayed by controller is 0 kw. Measured values are as follows: kw kvar kva pf Phase L Phase L Phase L Total L11D03-EN

21 3.4. DIGITAL INPUTS Type of inputs: Function selection: Contact type: Switching: Structure: Measurement: Open circuit voltage: Low level threshold: High level threshold: Maximum input voltage: Minimum input voltage: Noise filtering: all configurable from list Normally open or normally closed (programmable) Battery negative or battery positive (programmable) 47 k-ohms resistor to battery positive, 110k-ohms to battery negative. Analog voltage measurement. 70% of battery voltage 35% of battery voltage 85% of battery voltage +100VDC with respect to battery negative -70VDC with respect to battery negative yes 3.5. ANALOG SENDER INPUTS AND SENDER GROUND Type of inputs: Function selection: Structure: Measurement: Open circuit voltage: Short circuit current: Measurement range: Open circuit threshold: Resolution: Accuracy: Common mode voltage range: Noise filtering: all configurable, additional sender ground input from list 667 ohms resistor polarizing to 3.3VDC Analog resistor measurement. +3.3VDC 5mA 0 to 5000 ohms ohms ohms or lower 2 %+1 ohm (±7 ohms) ± 3VDC yes L11D03-EN

22 3.6. CHARGE INPUT TERMINAL The Charge terminal is both an input and output. When the engine is ready to run, this terminal supplies the excitation current to the charge alternator. The excitation circuit is equivalent to a 2W lamp. The threshold voltages for warning and shutdown alarm are adjustable through program parameter. Structure: battery voltage output through 100 ohm resistor voltage measurement input Output current: Voltage measurement resolution: Voltage measurement accuracy: Charge Fail Warning Threshold: Charge Fail Shutdown Alarm Threshold: Open circuit voltage: Overvoltage protection: Reverse voltage protection: 0.1VDC 2% + 0.1V adjustable adjustable battery positive > 500VDC continuous, with respect to battery negative -30VDC with respect to battery negative 3.7. MAGNETIC PICKUP INPUT Structure: Input impedance: Input voltage: Max common mode voltage: Frequency range: Resolution: Accuracy: Differential frequency measurement input 50 k-ohms 0.5VAC-RMS to 30VAC-RMS ± 5VDC 10Hz to 10 khz 1 rpm 0.2% + 1 rpm rpm) Flywheel teeth range: 1 to 500 Do not share MPU with other devices. L11D03-EN

23 3.8. MAINS CONTACTOR OUTPUT Structure: Max switching current: Max switching voltage: Max switching power: Relay output, normally closed contact. One terminal is internally connected to mains phase L1 input. 440VAC 3000VA 3.9. GENERATOR CONTACTOR OUTPUT Structure: Max switching current: Max switching voltage: Max switching power: Relay output, normally open contact. One terminal is internally connected to genset phase L1 input. 440VAC 4000VA DIGITAL OUTPUTS Structure: Function Max continuous current: Max switching voltage: Positive relay output, NO contact programmable function, selectable from list ADC 33 VDC L11D03-EN

24 3.11. INPUT/OUTPUT EXTENSION I/O Extension Connector The module provides resources for 32 additional digital inputs and 32 additional digital outputs. Digital inputs can be extended using DKG-188 Digital Input Extension modules, each one providing 8 inputs. Digital inputs are programmable through the main controller. The switching characteristic is not programmable and must be battery negative. Any function can be assigned to digital inputs. Digital outputs can be extended using DKG-186 Fet Extension modules, each one providing 8 outputs. Digital outputs have the same electrical characteristics as on board outputs. They have programmable functions through the main controller. Any function can be assigned to any output. Input and output extension modules are connected to the main controller in a cascade structure, in any order. The connection cable is provided with each extension module. L11D03-EN

25 3.12. RS-485 PORT Structure: Connection: Baud rate: Data type: Termination: Common mode voltage: Max distance: RS-485, non isolated. 3 wires (A-B-GND). Half duplex bauds, selectable 8 bit data, no parity, 1 bit stop External 120 ohms required -0.5 VDC to +7VDC, internally clamped by transient suppressors bauds (with 120 ohms balanced cable) bauds (with 120 ohms balanced cable) The RS-485 port features MODBUS-RTU protocol. Multiple modules (up to 128) can be paralleled on the same RS-485 bus for data transfer to automation or building management systems. The Modbus register list is available at Datakom technical support RS-232 PORT Description: Functionality: Connector: Connection: Baud rate: Data type: Max distance: Cable type: RS-232, non isolated. MODBUS RTU, External GSM modem, external PSTN modem DB-9 (9 pins male) 5 wires (Rx-Tx-DTR-CxD-GND). Full duplex bauds, selectable 8 bit data, no parity, 1 bit stop 15m Standard modem cable J1939-CANBUS PORT Structure: Connection: Data rate: Termination: Common mode voltage: Max distance: CANBUS, non isolated. 3 wires (CANH-CANL-GND). 250 kbps Internal 120 ohms provided -0.5 VDC to +15 VDC, internally clamped by transient suppressors. 200m with 120 ohm balanced cable L11D03-EN

26 3.15. USB DEVICE PORT USB Device Connector USB A to B Cable Description: Data rate: Connector: Cable length: Functionality: USB 2.0, not isolated, HID mode Full Speed 1.5/12 Mbits/s, auto detecting USB-B (printer connector) Max 6m Modbus, FAT32 for firmware upgrade (boot loader mode only) The USB-Device port is designed to connect the module to a PC. Using the RainbowPlus software, programming, control of the genset and monitoring of measured parameters are achieved. The RainbowPlus software can be downloaded from website. The connector on the module is of USB-B type. Thus A to B type USB cable should be used. This is the same cable used for USB printers. For more details about programming, control and monitoring please refer to RainbowPlus user manual. The battery voltage must be connected. L11D03-EN

27 3.16. GSM MODEM (OPTIONAL) The optional internal GSM modem offers the advantage of being internally powered and is fully compatible with the unit. It does not require any special setup. The 1800/1900 MHz magnetic antenna together with its 2 meter cable is supplied with the internal modem option. The antenna is intended to be placed outside of the genset panel for the best signal reception. SIM Card slot SIM Card extraction tab Antenna connector Magnetic antenna The module requires a GPRS enabled SIM card for full functionality. Voice-only type SIM cards will usually not function properly. Please refer to GSM Modem Configuration Guide for more details. L11D03-EN

28 SIM CARD EXTRACTION SIM CARD EXTRACTION/INSERTION SIM CARD PLACEMENT Description: Functionality: Quad-band GSM/GPRS 850/900/1800/1900MHz module. GPRS multi-slot class 12/12 GPRS mobile station class B Compliant to GSM phase 2/2+. Class 4 (2 900 MHz) Class 1 (1 1800/1900MHz) Web Client, SMTP, Modbus TCP/IP (client), SMS, Operating temp range: -40 C to +85 C Data speed: SIM card type: Antenna: Module certificates: max kbps (download), 85.6 kbps (upload) external SIM 3V/1.8V, GPRS enabled Quad band, magnetic, with 2m cable CE, FCC, ROHS, GCF, REACH LOCATION DETERMINATION VIA GSM The unit determines automatically the geographical position through the GSM network. No settings are necessary for this. This feature is especially useful for the remote monitoring where the controller will appear automatically at its geo-position or for mobile gensets. Although the controller supports also GPS location determination for more precise positioning, the GSM based location is free of charge, available everywhere, even where GPS signal is not available. The location precision will depend of the GSM system. In highly populated areas, the precision is good (a few hundred meters), but rural areas may lead to errors of a many kilometers. L11D03-EN

29 4. TOPOLOGIES Various topologies are selectable through program parameter. The topology is independently selectable for both genset and mains sections. In following drawings the connections are shown for the alternator. Current transformers are supposed connected to the alternator side. Similar topologies re available for the mains side as well SELECTING THE TOPOLOGY Generator Parameters s Topology Selection Mains Parameters s Topology Selection L11D03-EN

30 PHASE, 4 WIRE, STAR PHASE, 3 WIRE, DELTA L11D03-EN

31 PHASE, 4 WIRE, DELTA PHASE, 3 WIRE, DELTA, 2 CT (L1-L2) L11D03-EN

32 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3) PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2) L11D03-EN

33 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3) PHASE, 2 WIRE L11D03-EN

34 5. FUNCTIONALITIES The same unit provides different functionalities through parameter setting. Thus a single stock item will fulfill various duties, minimizing stock cost CT LOCATION SELECTION CTs may be placed at alternator or load busbars. The CT location selection is configured with Controller Configuration > CT Location parameter. When CTs are located at the alternator side, them mains current and power parameters will not be displayed. When CTs are located at load side, then both mains and genset currents and power parameters will be displayed, based on contactor positions. Please review AMF functionality connection diagrams for CT connection details AMF FUNCTIONALITY When AMF functionality is selected, the unit will monitor mains voltages, provide mains and genset contactor control, run the engine and provide engine and alternator instrumentation and fault monitoring. The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported. The unit provides control outputs for both contactors and motorized circuit breakers ATS FUNCTIONALITY When ATS functionality is selected, the unit will monitor mains voltages, provide mains and genset contactor control and issue a Remote Start signal to the engine controller. It will provide alternator instrumentation and fault monitoring. Engine instrumentation and protection will be insured by the engine controller REMOTE START FUNCTIONALITY When the Remote Start functionality is selected, the unit will wait for a Remote Start signal from external controller. Upon reception of this signal, it will run the engine, and provide engine and alternator instrumentation and fault monitoring. The genset contactor/mcb control functionality will be available. The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported. L11D03-EN

35 5.5 ENGINE CONTROLLER FUNCTIONALITY When the Engine Controller functionality is selected, genset electrical measurements and protections will be disabled. The unit is supposed to control an engine without alternator. When the Engine Control Mode is activated: -the unit will not display genset AC parameters (volts, amps, kw and pf). -genset voltage and frequency protections are disabled. However engine rpm protections will be active. Note that the engine controller functionality is compatible with both AMF and Remote Start modes. When AMF and Engine controller modes are selected, the unit will monitor the mains and will run the engine upon mains failure. This functionality is useful for the backup electric motor driven systems during mains failures, like fire pump or irrigation systems. When Remote Start and Engine controller modes are selected, the unit will start and stop the engine with external signal only. The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported. It is strongly recommended to wire speed detection through MPU or J1939-CANBUS and enter correct low and high rpm limit values in order to preserve engine speed protection. L11D03-EN

36 5.6. REMOTE DISPLAY UNIT FUNCTIONALITY The unit is able to become the remote display and control panel of another identical module. The connection between two modules is done through RS-485 ports. For the best results, a 120 ohms balanced, low capacitance cable should be used. The data rate between modules is selectable between 2400 and bauds. A high data rate offers better synchronization between modules, but the distance will be limited. Typically at bauds and with adequate cable, the distance will be 200m maximum. At 9600 bauds and adequate cable the distance can go up to 1200m. Below settings are necessary: PARAMETER MAIN UNIT REMOTE DISPLAY UNIT Annunciator Mode 0 1 RS-485 Enable 1 1 RS-485 Baud Rate any same as main unit Modbus Slave Address any same as main unit The remote display panel should be powered up with an isolated voltage source, like a wall adapter. Otherwise damages due to ground potential differences may occur HZ OPERATION The standard unit is also 400Hz enabled. The nominal frequency setting accepts up to 500Hz. Usual low and high limits will apply without any special setting. The measurement system of the unit allows frequencies up to 1000Hz to be measured precisely. However the display is limited to 650Hz. Frequencies over 650Hz will be displayed as 650Hz. The bandwidth of the harmonic analyzer is limited to 1800Hz. Thus in case of a 400Hz system, only the 3 rd harmonic will be displayed. The waveform display of a 400Hz signal will be represented with 10 points. It will not be as accurate as 50/60Hz signals. For more details please read chapter: Waveform Display & Harmonic Analysis. L11D03-EN

37 6. CONNECTION DIAGRAMS 6.1. AMF FUNCTIONALITY, CTs AT LOAD SIDE ALTERNATOR L1 LOAD L1 L2 L3 N MAINS L1 L2 L2 L3 L3 N N FUSE FUSE FUSE GC MC I I I MN-N MN-L3 MN-L2 MN-L1 MN-C RS BAT + BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG SND 1 SND 2 SND 3 USE SGND F IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 MPU+ MPU- / PGND CANH CANL USE F PGND USE 485-B F 485-A G-C G-L1 G-L2 G-L3 G-N I 1+ I 1- I SIM CARD! 8 to 36Vdc, 500mA max 300Vac, Hz 0.2 to 6.0 Aac I/O EXTENSION GSM ANTENNA USB-DEVICE BATTERY 12/24V Fuse S Starter Motor Crank Fuel Alarm Preheat D+ / WL Charge Alternator Oil Press. Sender Temp. Sender Fuel Lev. Sender Sender Gnd * 1 Low Oil Pressure High Temp Emergency Stop Spare Input 1 Spare Input 2 Spare Input 3 Force OFF Mode Low Coolant Level * 2 MPU J1939-H J1939-L * 2 To ECU * 2 To BMS *1 Connect to the engine body, close to the senders. 2 Ground from one end only. * L11D03-EN

38 6.2. AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE ALTERNATOR L1 LOAD L1L2L3 N MAINS L1 L2 L2 L3 L3 N N FUSE FUSE FUSE GC MC I I I I I MN-N MN-L3 MN-L2 MN-L1 MN-C FUSE RS BAT + BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG SND 1 SND 2 SND 3 SGND IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 FUSE IN 8 MPU+ MPU- / PGND CANH CANL PGND 485-B 485-A G-C G-L1 G-L2 G-L3 FUSE G-N I SIM CARD! 8 to 36Vdc, 500mA max 300Vac, Hz 0.2 to 6.0 Aac I/O EXTENSION GSM ANTENNA USB-DEVICE BATTERY 12/24V Fuse S Starter Motor Crank Fuel Alarm Preheat D+ / WL Charge Alternator Oil Press. Sender Temp. Sender Fuel Lev. Sender Sender Gnd * 1 Low Oil Pressure High Temp Emergency Stop Spare Input 1 Spare Input 2 Spare Input 3 Force OFF Mode Low Coolant Level * 2 MPU J1939-H J1939-L * 2 To ECU * 2 To BMS *1 Connect to the engine body, close to the senders. 2 Ground from one end only. * L11D03-EN

39 6.3. ATS FUNCTIONALITY ALTERNATOR L1 LOAD L1 L2 L3 N MAINS L1 L2 L2 L3 L3 N N FUSE FUSE FUSE GC MC I I I I I MN-N MN-L3 MN-L2 USE MN-L1 MN-C F USE RS BAT + BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG SND 1 SND 2 SND 3 SGND IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 MPU+ MPU- / PGND CANH CANL PGND 485-B F 485-A G-C G-L1 G-L2 USE G-L3 G-N I SIM CARD! 8 to 36Vdc, 500mA max 300Vac, Hz 0.2 to 6.0 Aac I/O EXTENSION GSM ANTENNA USB-DEVICE BATTERY 12/24V Fuse Remote Start Spare-1 Low Oil Pressure High Temp Emergency Stop Spare Input 1 Spare Input 2 Spare Input 3 Force OFF Mode Low Coolant Level F Alarm Spare-2 L11D03-EN

40 6.4. REMOTE START FUNCTIONALITY ALTERNATOR L1 LOAD L1 L2 L2 L3 L3 N N FUSE FUSE FUSE GC I I I I I MN-N MN-L3 MN-L2 MN-L1 MN-C RS BAT + BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG SND 1 SND 2 SND 3 SGND IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 MPU+ MPU- / PGND CANH CANL PGND 485-B 485-A G-C G-L1 G-L2 G-L3 G-N I SIM CARD! 8 to 36Vdc, 500mA max 300Vac, Hz 0.2 to 6.0 Aac I/O EXTENSION GSM ANTENNA USB-DEVICE BATTERY 12/24V Fuse S Starter Motor Crank Fuel Alarm Preheat D+ / WL Charge Alternator Oil Press. Sender Temp. Sender Fuel Lev. Sender Sender Gnd * 1 Low Oil Pressure High Temp Emergency Stop Spare Input 1 Spare Input 2 Spare Input 3 Force OFF Mode Low Coolant Level * 2 MPU J1939-H J1939-L * 2 To ECU * 2 To BMS *1 Connect to the engine body, close to the senders. 2 Ground from one end only. * L11D03-EN

41 6.5. ENGINE CONTROL FUNCTIONALITY I 3+ I 3- MN-N MN-L3 MN-L2 MN-L1 MN-C R S BAT + BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG SND 1 SND 2 SND 3 SGND IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 MPU+ MPU- / PGND CANH CANL PGND 485-B 485-A G-C G-L1 G-L2 G-L3 G-N I 1+ I 1- I 2+ I 2- I S M C A R D! 8 t o 3 6 d c, a x a c, z 0. 2 t o 6. 0 a c V m A m V H A I / O E X T E N S I O N - I G S M A N T E N N A U S B D E V C E BATTERY 12/24V S Fuse S t a r t e r M o t o r Crank Fuel Alarm Preheat Charge Alternator D+ / WL Oil Press. Sender Temp. Sender Fuel Lev. Sender 1 Sender Gnd * Low Oil Pressure High Temp Emergency Stop Spare Input 1 Spare Input 2 Spare Input 3 Force OFF Mode Low Coolant Level * 2 M P U J1939-H J1939-L * 2 * 2 T o E C U T o B M S * 1 C o n n e c t t o t h e e n g i n e b o d y, c l o s e t o t h e s e n d e r s. * 2 G r o u n d f r o m o n e e n d o n l y. L11D03-EN

42 6.6. REMOTE DISPLAY PANEL FUNCTIONALITY I I I I I MN-N MN-L3 MN-L2 MN-L1 MN-C RS BAT + BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG SND 1 SND 2 SND 3 SGND IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 MPU+ MPU- / PGND CANH CANL PGND 485-B 485-A G-C G-L1 G-L2 G-L3 G-N I SIM CARD! 8 to 36Vdc, 500mA max 300Vac, Hz 0.2 to 6.0 Aac I/O EXTENSION GSM ANTENNA USB-DEVICE Fuse Spare Input 1 Spare Input 2 Emergency Stop Spare Input 3 Spare Input 4 Spare Input 5 Spare Input 6 Spare Input 7 * 2 SUPPLY 12/24V Spare-1 Spare-2 Spare-3 Spare-4 To Main Control Panel RS-485 port L11D03-EN

43 7. TERMINAL DESCRIPTION Term Function Technical data Description 1 BATTERY POSITIVE +12 or 24VDC The positive terminal of the DC Supply. 2 BATTERY NEGATIVE O VDC Power supply negative connection. 3 DIGITAL OUTPUT 1 Protected Semiconductor Outputs This relay has programmable function, selectable from a list. Factory set as CRANK output. 4 DIGITAL OUTPUT 2 1A/28VDC This relay has programmable function, selectable from a list. Factory set as FUEL output. 5 DIGITAL OUTPUT 3 This relay has programmable function, selectable from a list. Factory set as ALARM output. 6 DIGITAL OUTPUT 4 This relay has programmable function, selectable from a list. Factory set as PREHEAT output. 7 CHARGE Input and output Connect the charge alternator s D+ terminal to this terminal. This terminal will supply the excitation current and measure 8 ANALOG SENDER 1 (OIL PRESSURE SENDER) 9 ANALOG SENDER 2 (COOLANT TEMP. SENDER) 10 ANALOG SENDER 3 (FUEL LEVEL SENDER) Resistor measuring input, ohms the voltage of the charge alternator. Connect to the oil pressure sender. Do not connect the sender to other devices. Connect to the coolant temperature sender. Do not connect the sender to other devices. Connect to the fuel level sender. Do not connect the sender to other devices. 11 SENDER GROUND Input Ground potential for analog senders. Connect to the engine body, close to senders. Term Function Technical data Description 12 DIGITAL INPUT 1 Digital Inputs, 0-30Vdc The input has programmable function. Factory set as LOW OIL PRESSURE SWITCH. 13 DIGITAL INPUT 2 The input has programmable function. Factory set as HIGH TEMP SWITCH. 14 DIGITAL INPUT 3 The input has programmable function. Factory set as EMERGENCY STOP. 15 DIGITAL INPUT 4 The input has programmable function. Factory set as SPARE INPUT DIGITAL INPUT 5 The input has programmable function. Factory set as SPARE INPUT DIGITAL INPUT 6 The input has programmable function. Factory set as SPARE INPUT DIGITAL INPUT 7 The input has programmable function. Factory set as FORCE OFF MODE. 19 DIGITAL INPUT 8 AC signal driving output and detector input L11D03-EN This input is specially designed for LOW COOLANT LEVEL detection. The terminal is driven with a low amplitude pure sinus waveform. It does not cause waer of the detector electrode.

44 Term Function Technical data Description 20 MPU + Analog input, 0.5 to Connect one terminal of the MPU unit to 30V-AC this input. Use a twisted cable pair or coaxial cable for best results. 21 MPU - / PROTECTION GROUND Output 0Vdc 22 CANBUS-H Digital communication 23 CANBUS-L port Connect one terminal of the MPU unit to this input. Use a twisted cable pair or coaxial cable for best results. Connect the protective shield of the CANBUS cable to this terminal. Connect the J1939 port of an electronic engine to these terminals. The 120 ohm terminating resistors are inside the unit. Please do not connect external resistors. Use a twisted cable pair or coaxial cable for best results. Term Function Technical data Description 21 PROTECTION GROUND Output 0Vdc Connect the protective shield of the RS- 485 cable to this terminal. 25 RS-485 B Digital communication Connect the A-B data lines of the RS RS-485 A port link to these terminals. Term Function Technical data Description 51 GENERATOR CONTACTOR Relay output, 16A-AC This output provides energy to the generator contactor. If the generator phases do not have acceptable voltage or frequency values, the generator contactor will be de-energized. In order to provide extra security, the normally closed contact of the mains contactor should be serially connected to this output. 52 GEN-L1 Generator phase Connect the generator phases to these 54 GEN-L2 inputs, 0-300V-AC inputs. The generator phase voltages 56 GEN-L3 upper and lower limits are programmable. 58 GENERATOR NEUTRAL Input, 0-300V-AC Neutral terminal for the generator phases. Term Function Technical data Description 59 CURR_1+ Current transformer Connect the generator current transformer inputs, 5A-AC terminals to these inputs. 60 CURR_1- Do not connect the same current transformer to other instruments otherwise 61 CURR_2+ a unit fault will occur. Connect each terminal of the transformer 62 CURR_2- to the unit s related terminal. Do not use common terminals. Do not use 63 CURR_3+ grounding. Correct polarity of connection is vital. 64 CURR_3- The rating of the transformers should be identical for each of the 3 phases. The secondary winding rating shall be 5 Amperes. (ex: 200/5 Amps). L11D03-EN

45 Term Function Technical data Description 65 MAINS NEUTRAL Input, 0-300V-AC Neutral terminal for the mains phases. 67 MAINS-L3 Mains phase inputs, 0-300V-AC Connect the mains phases to these inputs. The mains voltages upper and lower limits are programmable. 69 MAINS-L2 71 MAINS-L1 72 MAINS CONTACTOR Relay output, 16A-AC This output provides energy to the mains contactor. If the mains phases do not have acceptable voltages, the mains contactor will be de-energized. In order to provide extra security, the normally closed contact of the generator contactor should be serially connected to this output. L11D03-EN

46 8. TECHNICAL SPECIFICATIONS DC Supply Range: 9.0 to 33.0 V-DC. DC power consumption: 250 ma-dc 125 ma-dc 500 ma-dc 250 ma-dc Alternator voltage: 0 to 330 V-AC (Ph-N), 0 to 570V Ph-Ph Alternator frequency: Hz. Mains voltage: 0 to 330 V-AC (Ph-N), 0 to 570V Ph-Ph Mains frequency: Hz. Current Inputs: from current transformers.../5a. CT Range: 5/5A to 5000/5A VT Range: 0.1/1 to 6500 / 1 kw Range: 0.1kW to kw Accuracy: Voltage: 0.5%+1digit Current: 0.5%+1 digit Frequency: 0.5%+1 digit Power(kW,kVAr): 1.0%+2digit Power factor: 0.5 %+1digit Digital inputs: input voltage 0 to 36 V-DC. Analog input range: ohms. Mains and genset contactor outputs: 16Amps@250V DC Outputs: Relay outputs, positive switching NO contacts. 10Amps@28V-DC Cranking dropouts: survives 0V for 100ms. Magnetic pickup voltage: 0.5 to 30V-RMS. Magnetic pickup frequency: 10 to Hz. Charge Alternator Excitation: Ethernet Port: 10/100 Mbits USB Device: USB 2.0 Full speed USB Host: USB 2.0 Full speed RS-485 Port: selectable baud rate RS-232 Port: selectable baud rate Operating temperature: -20 C to 70 C (-4 to +158 F). Storage temperature: -40 C to 80 C (-40 to +176 F). Maximum humidity: 95% non-condensing. IP Protection: IP54 from front panel, IP30 from the rear. Dimensions: 200 x 148 x 46mm (WxHxD) Panel Cut-out Dimensions: 176 x 121 mm minimum. Weight: 450 g (approx.) Case Material: High Temperature, non-flammable, ROHS compliant ABS/PC Mounting: Flush mounted with rear retaining plastic brackets. EU Directives Conformity -2006/95/EC (low voltage) -2004/108/EC (electro-magnetic compatibility) Norms of reference: EN (safety requirements) EN (EMC requirements) UL Compatibility: UL 6200, Controls for Stationary Engine Driven Assemblies (Certificate Number E314374) CSA Compatibility: CAN/CSA C22.2 No Industrial Control Equipment L11D03-EN

47 9. DESCRIPTION OF CONTROLS 9.1. FRONT PANEL FUNCTIONALITY Graphic LCD screen Mimic Diagram (sysem status) Mains Contactor control in RUN mode Fault condition indicators Next display group Next screen in the same group. LAMP TEST if held pressed Genset Contactor control in RUN mode Previous display group Previous screen in the same group. ALARM Mute TEST mode button RUN mode button AUTO mode button STOP mode button When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the service request output function will be active. The service request can also create a fault condition of any level following parameter setting. The service request output function may be assigned to any digital output using Relay Definition program parameters. Also relays on an extension module may be assigned to this function. To turn off the SERVICE REQUEST led, and reset the service period, press together the ALARM MUTE and LAMP TEST keys for 5 seconds. L11D03-EN

48 9.2. PUSHBUTTON FUNCTIONS BUTTON FUNCTION Selects TEST mode. The genset runs and takes the load. Selects RUN mode. The genset runs off-load. Selects AUTO mode. The genset runs when necessary and takes the load. Selects OFF mode. The genset stops. Selects next display screen in the same display group. LAMP TEST when held pressed. Selects previous display group. Selects next display group. Selects previous display screen in the same display group. Resets the ALARM RELAY. Manual MAINS CONTACTOR control in RUN mode. Manual GENSET CONTACTOR control in RUN mode. When held pressed for 5 seconds, enters PROGRAMMING mode. Makes factory reset. Please review chapter RESETTING TO FACTORY DEGAULTS for more details. When held pressed for 5 seconds, resets service request counters. Please review chapter SERVICE REQUEST ALARM for more details. L11D03-EN

49 9.3. DISPLAY SCREEN ORGANIZATION The unit measures a large number of electrical and engine parameters. The display of the parameters is organized as PARAMETER GROUPS and items in a group. Navigation between different groups are made with and buttons. Each depression of the button will cause the display to switch to the next group of parameters. After the last group the display will switch to the first group. Each depression of the button will cause the display to switch to the previous group of parameters. After the first group the display will switch to the last group. Navigation inside a groups is made with and buttons. Each depression of the button will cause the display to switch to the next parameter in the same group. After the last parameter the display will switch to the first parameter. Each depression of the button will cause the display to switch to the previous parameter in the same group. After the first parameter the display will switch to the last parameter. Below is a basic list of parameter groups: Genset Parameters: Genset voltages, currents, kw, kva, kvar, pf etc... Engine Parameters: Analog sender readings, rpm, battery voltage, engine hours, etc... J1939 Parameters: Opens only if the J1939 port is enabled. The unit is able to display a long list of parameters, under the condition that the engine sends this information. A complete list of available readings is found at chapter J1939 CANBUS ENGINE SUPPORT. Mains Parameters: Mains voltages, currents, kw, kva, kvar, pf etc... Mains currents and power parameters are displayed only when CT Selection is made as LOAD SIDE. Otherwise mains current and power related parameters will not be displayed. Scopemeter Display: This group display waveforms of voltages and currents as an oscilloscope. All Ph- N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate waveform distortions and harmonic loads. Graphical Harmonic Analysis Results: This group displays harmonic composition of voltages and currents. All Ph-N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate the harmonic caused by complex loads. Only harmonics above 2% are represented in the graphics because of the display resolution. In order to see all harmonic levels please use the Alphanumerical Harmonic Analysis Results. Alphanumerical Harmonic Analysis Results: This group displays harmonic composition of voltages and currents with 0.1% resolution. All Ph-N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate the harmonic caused by complex loads. Alarm Display: This group displays all existing alarms, one screen per alarm. When there is no more alarm to display it will show END OF ALARM LIST. GSM Modem Parameters: Signal strength, counters, communication status, IP addresses etc... Ethernet Parameters: Ethernet connection status, counters, IP addresses etc... Status & Counters Groups: This group includes various parameters like genset status, service counters, date-time, firmware version etc... L11D03-EN

50 9.4. AUTOMATIC DISPLAY SCROLL The unit will automatically scroll all Mains, Genset and Engine measurements with programmable interval. The scroll period setting can be performed using the RainbowPlus program through Module > Screen options. Eventually the same parameter can be modified through the front panel programming menu. The related parameter is Controller Configuration > Screen Scroll Timer. If the Screen Scroll Timer is set to zero, then scrolling will be disabled. When a front panel button is pressed, the scrolling is suspended during 2 minutes. If a fault condition occurs, the display will automatically switch to the ALARM LIST page. L11D03-EN

51 9.5. MEASURED PARAMETERS The unit performs a detailed set of AC measurements. Mains currents and power parameters (listed in blue color) are measured and displayed only if CTs are placed at load side. please see connection diagrams section for more details. The list of measured AC parameters is below: Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutral Mains average voltage phase to neutral Mains voltage phase L1-L2 Mains voltage phase L2-L3 Mains voltage phase L3-L1 Mains frequency Mains current phase L1 Mains current phase L2 Mains current phase L3 Mains average current Mains kw phase L1 Mains kw phase L2 Mains kw phase L3 Mains total kw Mains kva phase L1 Mains kva phase L2 Mains kva phase L3 Mains kvar phase L1 Mains kvar phase L2 Mains kvar phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current Below engine parameters are always measured: Engine speed (rpm) Battery voltage, Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen average voltage phase to neutral Gen voltage phase L1-L2 Gen voltage phase L2-L3 Gen voltage phase L3-L1 Gen frequency Gen current phase L1 Gen current phase L2 Gen current phase L3 Gen average current Gen kw phase L1 Gen kw phase L2 Gen kw phase L3 Gen total kw Gen kva phase L1 Gen kva phase L2 Gen kva phase L3 Gen kvar phase L1 Gen kvar phase L2 Gen kvar phase L3 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Gen Neutral current The unit features 4 analog senders, fully configurable for the name and function. Below is a typical list of analog senders, capable of changing following configuration: Coolant temperature Oil pressure (bar, kpa) Fuel level (%, lt) Oil temperature ( C, F) Items in blue are measured only when current transformers are at the load side. L11D03-EN

52 9.6. LED LAMPS Mains available led Shutdown alarm indicator Mains Contactor On led Warning indicator Service request indicator Genset Contactor on led Genset available led TEST mode indicator RUN mode indicator AUTO mode indicator STOP mode indicator STATUS LEDS: ALARM: Turns on when a shutdown alarm or loaddump condition exists. WARNING: Turns on when a warning condition exists SERVICE REQUEST: Turns on when at least one of the service counters has expired. MODE LEDS: Each led turns on when the related mode is selected, either locally or remotely. MIMIC DIAGRAM LEDS: MAINS AVAILABLE: This led turns on when all mains phase voltages and the mains frequency are within limits. If enabled, the mains phase rotation order must be also right. When any digital input is defined as Remote Start, this led will reflect the status of the input. When a Simulate Mains signal is present, then mains status will become available. When a Force to Start signal is present, then the mains status will become not available. MAINS CONTACTOR ON: Turns on when the mains contactor is activated. GENSET CONTACTOR ON: Turns on when the genset contactor is activated. GENSET AVAILABLE: This led turns on when all genset phase voltages and the genset frequency are within limits. If enabled, the genset phase rotation order must be also right. If a Remote Start input is defined, then the Mains led will reflect the input status. Simulate Mains and Force to Start signals will also affect this led. L11D03-EN

53 10. WAVEFORM DISPLAY & HARMONIC ANALYSIS The unit features waveform display together with a precision harmonic analyzer for both mains and genset voltages and currents. Both phase to neutral and phase to phase voltages are available for analysis, thus 18 channels in total are possible. In order to enable display and analysis of mains currents, current transformers must be placed at load side. Available channels are: Mains volts: V1, V2, V3, U12, U23, U31 Mains currents: I1, I2, I3 Genset volts: V1, V2, V3, U12, U23, U31 Genset currents: I1, I2, I3 Scopemeter Display The waveform display memory is of 100 samples length and 13 bit resolution, with a sampling rate of 4096 s/s. Thus one cycle of a a 50Hz signal is represented with 82 points. The vertical scale is automatically adjusted in order to avoid clipping of the signal. The waveform is displayed on the device screen, and with more resolution on PC screen through the RainbowPlus program. The display memory is also available in the Modbus register area for third party applications. For more details please check chapter MODBUS Communications. The waveform display is updated twice a second. All channels may be scrolled using buttons. and L11D03-EN

54 The harmonic analyzer consists on a Fast Fourier Transform (FFT) algorithm which is run twice a second on the selected channel. The sample memory is 1024 samples length and 13 bits resolution with a sampling rate of 4096 s/s. The theory says that a periodic signal may have only odd multiples of the main frequency. Thus in a 50Hz network, harmonics will be found only at 150, 250, 350, 450 Hz etc... The unit is able to analyze up to 1800Hz and up to 31th harmonic, whichever is smaller. Thus in a 50Hz system all 31 harmonics will be displayed, but in a 60Hz system only 29 harmonics will come to the screen. In case of a 400Hz system, only the 3 rd harmonic will be displayed. Graphical Harmonic Table Alphanumeric Harmonics Table Harmonic are represented by 2 different ways on the device display. The first one is a graphical representation allowing one sight perception of the harmonic structure. Because of the display resolution, only harmonics above 2% are displayed. The second display is alphanumeric, thus all harmonics are displayed with 0.1% resolution in order to provide more detailed information. On RainbowPlus program, harmonics and waveform are displayed on a single screen with more resolution. RainbowPlus Scada section: Harmonic Analysis and Waveform Display L11D03-EN

55 11. DISPLAYING EVENT LOGS The unit features more than 400 event logs with date-time stamp and full snapshot of measured values at the moment that the event has occurred. Stored values in an event record are listed below: -event number -event type / fault definition (see below for various event sources) -date and time -operation mode -operation status (on-load, on-mains, cranking, etc...) -engine hours run -mains phase voltages: L1-L2-L3 -mains frequency -genset phase voltages: L1-L2-L3 -genset phase currents: L1-L2-L3 -genset frequency -genset total active power (kw) -genset total power factor -oil pressure -engine temperature -fuel level -oil temperature -canopy temperature -ambient temperature -engine rpm -battery voltage -charge voltage Possible event sources are various. Every source can be individually enabled or disabled: Event enable selection tab Program mode entrance event: recorded with the password level when program mode is entered. Periodic event: recorded every 30 minutes when the engine is running, and every 60 minutes anyway. Mode change event: recorded when the operation mode is changed. Shutdown/loaddump/warning events: recorded when the related fault condition occurs. Mains fail/restore events: recorded when mains status is changed Engine started/stopped events: recorded when engine status is changed Genset on_load/off_load events: recorded when the genset loading status is changed L11D03-EN

56 Event logs are displayed within the program mode menu. This is designed in order to reduce the interference of event logs with other measurement screens. To enter the event display, press together and buttons for 5 seconds. When the program mode is entered, below password entry screen will be displayed. Press 2 buttons for 5 seconds Skip the password entry screen by pressing the button 4 times. The screen below left will come. Press again the button. The last stored event will open, as in the below-right picture. The first page will display the event number, event type, fault type and date-time information. When displaying event logs: button will display the next information in the same event button will display the previous information in the same event button will display the same information of the previous event button will display the same information of the next event. L11D03-EN

57 12. STATISTICAL COUNTERS The unit provides a set of non-resettable incremental counters for statistical purposes. The counters consist on: -total genset kwh -total genset kvarh inductive -total genset kvarh capacitive -total genset export kwh -total mains kwh -total mains kvarh -total mains kvah -total engine hours -total engine starts -total fuel filled in the tank -engine hours to service-1 -time to service-1 -engine hours to service-2 -time to service-2 -engine hours to service-3 -time to service-3 These counters are kept in a non-volatile memory and are not affected from power failures FUEL FILLING COUNTER The unit offers a temper-proof incremental counter for fuel filling. Related parameters are: Parameter Definition Unit Min Max Fuel Pulses from MPU input Required value Fuel Pulses per Volume any Description 0: MPU input is used for engine speed detection 1: MPU input is used for reading the flowmeter pulses during fuel filling. This is the number of pulses produced by the flowmeter for the unit volume. This parameter is characteristic of the flowmeter used and should be set according to the flowmeter data. Fuel Counter Unit Lt/gal - - any This is the unit for the fuel counter Fuel Counter Type This parameter determines the purpose of fuel pulses 0: Fuel filling pulses, increment fuel counter 1: Fuel consumption pulses, display consumption. The quantity of the fuel filled in the tank is read from pulses generated by a flowmeter installed at the tank filling hose. Flowmeter pulse outputs will be connected to the MPU input of the controller. The controller will count pulses and convert them in liters (or gallons) then increment the fuel filling counter by the calculated amount. The fuel filling counter is visible through Scada and Central Monitoring. Thus the genset operator can confirm fuel invoices with the real amount of fuel filled in the tank, preventing corruption. L11D03-EN

58 12.2. FUEL CONSUMPTION MONITORING The unit is capable to display the actual fuel consumption of the engine by two different ways: Through J1939 fuel consumption information By counting fuel consumption pulses. If the engine is sending the fuel rate through J1939 messaging, then the unit will directly display the fuel consumption information coming from the ECU. If a flowmeter is installed at the fuel suction hose of the engine, then the unit is also capable of counting these pulses, calculating and displaying the fuel consumption. Related parameters are: Parameter Definition Unit Min Max Fuel Pulses from MPU input Required Value Fuel Pulses per Volume any Description 0: MPU input is used for engine speed detection 1: MPU input is used for reading the flowmeter pulses during fuel filling. This is the number of pulses produced by the flowmeter for the unit volume. This parameter is characteristic of the flowmeter used and should be set according to the flowmeter data. Fuel Counter Unit Lt/gal - - any This is the unit for the fuel counter Fuel Counter Type This parameter determines the purpose of fuel pulses 0: Fuel filling pulses, increment fuel counter 1: Fuel consumption pulses, display consumption. L11D03-EN

59 13. OPERATION OF THE UNIT QUICK START GUIDE STOPPING THE ENGINE: Press STOP STARTING THE ENGINE: Press RUN button button MANUAL LOAD TRANSFER: Use MAINS and GENSET buttons. LOAD TEST: Press TEST button. The genset will run and take the load. AUTOMATIC OPERATION: Press AUTO button. Check that AUTO READY led is illuminated. Mode can be changed anytime without negative effect. Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode STOP MODE The STOP mode is entered by pressing the In this mode, the genset will be in a rest state. button. When STOP mode is selected, if the genset is running under load, then it will be immediately unloaded. The engine will continue to run during Cooldown Timer and will stop afterwards. If the STOP button is pressed again, then the engine will immediately stop. If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur. In this mode, the mains contactor will be energized only if mains phase voltages and frequency are within the programmed limits. If enabled, the mains phase order is also checked. If a Remote Start or Force to Start signal arrives in STOP mode, the genset will not start until AUTO mode is selected. L11D03-EN

60 13.3. AUTO MODE The AUTO mode is entered by pressing the button. The AUTO mode is used for the automatic transfer between genset and mains. The controller will constantly monitor the mains availability. It will run the engine and transfer the load when a mains failure occurs. If a panel lock input is defined and signal is applied, then mode change will not occur. However display navigation buttons are still enabled and parameters may be visualized. The mains availability evaluation sequence is below: If at least one of the mains phase voltages or the mains frequency is outside limits, the mains will be supposed failing. Otherwise mains is available. If a Simulate Mains signal is present, then mains are made available If a Force to Start signal is present, then mains are unavailable If a Remote Start input is defined, then this signal decides of mains availability. When mains are evaluated as unavailable then an engine start sequence begins: The unit waits during Engine Start Delay for skipping short mains failures. If the mains is restored before the end of this timer, the genset will not start. The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer. The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay will be immediately deactivated. See section Crank Cutting for more details. The engine will run at idle speed during Idle Speed Timer. The engine will run unloaded during engine heating timer. If alternator phase voltages, frequency and phase order are correct, the unit will wait for the generator contactor period and the generator contactor will be energized. When mains are evaluated as available again then an engine stop sequence begins: The engine will continue to run for the mains waiting period to allow mains voltages to stabilize. Then the generator contactor is deactivated and the mains contactor will be energized after mains contactor timer. If a cooldown period is given, the generator will continue to run during the cooldown period. Before the end of cooldown, the unit will reduce the engine speed to idle speed. At the end of cooldown, the fuel solenoid will be de-energized, the stop solenoid will be energized for Stop Solenoid timer and the diesel will stop. The unit will be ready for the next mains failure. If the operation of the genset is disabled by the weekly schedule, then the AUTO led will flash, and the operation of the genset will be as in the OFF mode. L11D03-EN

61 13.4. RUN MODE, MANUAL CONTROL The RUN mode is entered by pressing the button. When the RUN mode is selected, the engine will be started regardless of the mains availability. The starting sequence is as described below: The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer. The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay will be immediately deactivated. See section Crank Cutting for more details. The engine will run at idle speed during Idle Speed Timer. The engine will run unloaded until another mode is selected.. The RUN mode allows also manual contactor control through MC and GC buttons. When a contactor button is pressed, the related contactor will change position. Thus if it was on, then it will turn off. If it was off then it will turn on. If the other contactor was on, then it will turn off, the controller will wait for the related contactor timer and the contactor will turn on. This will prevent manual closure of both contactors. If uninterrupted transfers are allowed, then the unit will check the synchronization. If synchronization is complete, then it will make an uninterrupted transfer, where both contactors will be on for a short while. If Emergency Backup mode is enabled and if the mains are off, then the mains contactor will be deactivated and the generator contactor will be activated. When the mains are on again, a reverse changeover to the mains will be performed, but the engine will keep running unless another mode is selected. In order to stop the engine press button or select another mode of operation TEST MODE The TEST mode is entered by pressing the button. The TEST mode is used in order to test the genset under load. Once this mode is selected, the engine will run as described in the AUTO mode, regardless of the mains availability and the load will be transferred to the genset. The genset will feed the load indefinitely unless another mode is selected. L11D03-EN

62 14. PROTECTIONS AND ALARMS The unit provides 3 different protection levels, being warnings, loaddumps and shutdown alarms. 1- SHUTDOWN ALARMS: These are the most important fault conditions and cause: - The ALARM led to turn on steadily, - The genset contactor to be released immediately, - The engine to be stopped immediately, - The Alarm digital output to operate. 2- LOAD_DUMPS: These fault conditions come from electrical trips and cause: - The ALARM led to turn on steadily, - The genset contactor to be released immediately, - The engine to be stopped after Cooldown period, - The Alarm digital output to operate. 3- WARNINGS: These conditions cause: - The WARNING led to turn on steadily, - The Alarm digital output to operate. If a fault condition occurs, the display will automatically switch to the ALARM LIST page. Alarms operate in a first occurring basis: -If a shutdown alarm is present, following shutdown alarms, loaddumps and warnings will not be accepted, -If a loaddump is present, following loaddumps and warnings will not be accepted, -If a warning is present, following warnings will not be accepted. If the ALARM MUTE button is pressed, the Alarm output will be deactivated; however the existing alarms will persist and disable the operation of the genset. Alarms may be of LATCHING type following programming. For latching alarms, even if the alarm condition is removed, the alarms will stay on and disable the operation of the genset. Existing alarms may be canceled by pressing one of the operating mode buttons: Most of the alarms have programmable trip levels. See the programming chapter for adjustable alarm limits. L11D03-EN

63 14.1. DISABLING ALL PROTECTIONS The unit allows any digital input to be configured as Disable Protections. This input configuration is used in cases where the engine is required to run until destruction. This may be the case under critical conditions like firefighting or other emergency cases. This input should be configured as a Warning. Thus when protections are disabled, a warning message will immediately appear on the screen. When protections are disabled, all shutdown alarms and loaddumps will become warnings. They will appear on the screen, but will not affect genset operation. The input may be constantly activated, or preferably it may be activated by an external key activated switch in order to prevent unauthorized activation. Disabling protections will allow the genset run until destruction. Place written warnings about this situation in the genset room SERVICE REQUEST ALARM The SERVICE REQUEST led is designed to help the periodic maintenance of the genset to be made consistently. The periodic maintenance is basically carried out after a given engine hours (for example 200 hours), but even if this amount of engine hours is not fulfilled, it is performed after a given time limit (for example 12 months). The unit offers 3 independent service counter sets in order to enable different service periods with different priorities. The fault level created upon expiration of service timers may be set as Warning, Loaddump or Shutdown. Thus different levels of fault conditions may be generated at different overrun levels. Each service counter set has both programmable engine hours and maintenance time limit. If any of the programmed values is zero, this means that the parameter will not be used. For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours, there will be no time limit. If the engine hours is also selected as 0 hours this will mean that this service counter set is not operative. When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the service request output function will be active. The service request can also create a fault condition of any level following parameter setting. The service request output function may be assigned to any digital output using Relay Definition program parameters. Also relays on an extension module may be assigned to this function. To turn off the SERVICE REQUEST led, and reset the service period, press together the ALARM MUTE and LAMP TEST keys for 5 seconds. The remaining engine hours and the remaining time limits are kept stored in a non-volatile memory and are not affected from power supply failures. The time and engine hours to service are displayed in the GENSET STATUS menu group. L11D03-EN

64 14.3. SHUTDOWN ALARMS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. GENSET LOW / HIGH FREQUENCY GENSET LOW / HIGH RPM GENSET LOW / HIGH VOLTAGE LOW / HIGH BATTERY VOLTAGE FAIL TO START LOW CHARGE VOLTAGE J1939 ECU FAIL VOLTAGE UNBALANCE CURRENT UNBALANCE OVERCURRENT PICKUP SIGNAL LOST SERVICE REQUEST Set if the generator frequency is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. Another high frequency shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately. Set if the generator rpm is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. The high rpm overshoot limit is always monitored and stops the engine immediately. Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. Set if the genset battery voltage is outside programmed limits. Low and high limits are separately programmable. The detection delay is also programmable. Set if the engine is not running after programmed number of start attempts. Set if the charge alternator voltage is below the programmed limit. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. Set if no information has been received during 3 seconds from the ECU of the electronic engine. This fault condition is only controlled when fuel is on. Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable. Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable. Set if the rpm measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer. The action of signal loss is programmable. Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both and buttons during 5 seconds. The screen will display Completed! L11D03-EN

65 14.4. LOADDUMP ALARMS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. VOLTAGE UNBALANCE CURRENT UNBALANCE OVERCURRENT OVERLOAD REVERSE POWER GENSET PHASE ORDER FAIL MAINS CB FAIL TO OPEN GENSET CB FAIL TO CLOSE PICKUP SIGNAL LOST SERVICE REQUEST UNIT LOCKED UNKNOWN TOPOLOGY Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable. Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable. Set if the genset power (kw) supplied to the load goes over the Overload Load Dump limit for Overload Timer. If the power goes below the limit before expiration of the timer then no alarm will be set. Set if the genset power (kw) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set. Set if the fault is enabled and the genset phase order is reverse. Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open/Close Fail Timer. Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open/Close Fail Timer. Set if the rpm measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer. The action of signal loss is programmable. Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both and buttons during 5 seconds. The screen will display Completed! Set if the controller is remotely locked. Set if the automatic topology determination is active, and the topology cannot be determined during Holdoff timer after the engine runs. L11D03-EN

66 14.5. WARNINGS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. All warnings can be made latching by enabling a single program parameter: Controller Configuration >Latch All Warnings Latch All Warnings GENSET LOW / HIGH FREQUENCY GENSET LOW / HIGH RPM GENSET LOW / HIGH VOLTAGE LOW / HIGH BATTERY VOLTAGE FAIL TO STOP LOW CHARGE VOLTAGE Set if the generator frequency is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. Another high frequency shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately. Set if the generator rpm is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. The high rpm overshoot limit is always monitored and stops the engine immediately. Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. Set if the genset battery voltage is outside programmed limits. Low and high limits are separately programmable. The detection delay is also programmable. Set if the engine has not stopped before the expiration of the Stop Timer. Set if the charge alternator voltage is below the programmed limit. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. L11D03-EN

67 J1939 ECU FAIL VOLTAGE UNBALANCE CURRENT UNBALANCE OVERCURRENT OVERCURRENT REVERSE POWER MAINS PHASE ORDER FAIL GENSET CB FAIL TO CLOSE / OPEN MAINS CB FAIL TO CLOSE PICKUP SIGNAL LOST SERVICE REQUEST Set when an engine fault code is received from the ECU of the electronic engine. This fault will not cause an engine stop. If necessary, the engine will be stopped by the ECU. Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable. Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable. Set if at least one of the genset phase currents goes over the Overcurrent Limit. Set if the genset power (kw) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set. Set if the mains phase order checking is enabled, mains phases are present and mains phase order is reversed. This fault prevents the Mains Contactor to close. Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open/Close Fail Timer. Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open/Close Fail Timer. Set if the rpm measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer. The action of signal loss is programmable. Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both and buttons during 5 seconds. The screen will display Completed! EEPROM WRITE FAULT ENGINE RUNNING AUTO NOT READY GPS DISCONNECTED GPS SIGNAL LOST Set if the internal non-volatile memory cannot be written. Set if the engine is running while the fuel output is not energized. Set if the genset is not in AUTO mode or a fault condition or the weekly schedule prevents the automatic starting of the genset. Set if the serial communication with the GPS is lost. Set if the communication with the GPS module is functional, but the GPS signal level is insufficient to determine the geo-location. L11D03-EN

68 14.6. NON-VISUAL WARNINGS These warnings are not announced at the device front panel, however they appear in event logs, transferred to the Scada and cause SMS and sending. FUEL THEFT FUEL FILLING MAINTENANCE DONE Engine is not running: If the fuel level measured from the sender input falls by 20% or more in one hour, then Fuel Theft warning occurs (the detection delay is 10 sec, not adjustable). Engine is running: If the fuel level measured from the sender input falls by 2x hourly fuel consumption percentage or more, then Fuel Theft warning occurs. If the fuel level measured from the sender input is increased by 20% or more in one hour, then Fuel Filling non-visual warning occurs (the detection delay is 10 seconds, not adjustable). Sent when the periodic maintenance counters are manually reset. L11D03-EN

69 15. PROGRAMMING RESETTING TO FACTORY DEFAULTS In order to resume to the factory set parameter values: -hold pressed the STOP, LAMP TEST and ALARM MUTE buttons for 5 seconds, - RETURN TO FACTORY SET will be displayed -immediately press and hold pressed RIGHT ARROW button for 5 seconds -factory set values will be reprogrammed to the parameter memory. Hold pressed STOP, LAMP TEST and ALARM MUTE Hold pressed RIGHT ARROW L11D03-EN

70 The program mode is used to adjust timers, operational limits and the configuration of the unit. Although a free PC program is provided for programming, every parameter may be modified through the front panel, regardless of the operating mode. When modified, program parameters are automatically recorded into a non-erasable memory and take effect immediately. The program mode will not affect the operation of the unit. Thus programs may be modified anytime, even while the genset is running ENTERING THE PROGRAMMING MODE To enter the program mode, press together buttons for 5 seconds. When the program mode is entered, below password entry screen will be displayed. Press 2 buttons for 5 seconds A 4 digit password must be entered using buttons. The buttons modify the value of the current digit. The buttons navigate between digits. The unit supports 3 password levels. The level_1 is designed for field adjustable parameters. The level_2 is designed for factory adjustable parameters. The level_3 is reserved. It allows recalibration of the unit. The password level-1 is factory set to 1234 and the password level-2 is factory set to Passwords are not front panel adjustable. If a wrong password is entered, the unit will still allow access to the program parameters, but in read-only mode. If password 0000 is entered, only EVENT LOG file will be available. L11D03-EN

71 15.3. NAVIGATING BETWEEN MENUS The program mode is driven with a two level menu system. The top menu consists on program groups and each group consists on various program parameters. When program mode is entered, a list of available groups will be displayed. Navigation between different groups are made with buttons. Selected group is shown in reverse video (blue on white). In order to enter inside a group, please press button. In order to exit from the group to the main list please press button. If inside the group then exit to main PGM menu Enter inside the group Next group Previous group Navigation inside a group is made also with buttons. A list of available parameters will be displayed. Selected parameter is shown in reverse video (blue on white). In order display/change the value of this parameter, please press button. Parameter value may be increased and decreased with buttons. If these keys are hold pressed, the program value will be increased/decreased by steps of 10. When a program parameter is modified, it is automatically saved in memory. If button is pressed, next parameter will be displayed. If displayed. button is pressed, then the list of parameters in this group will be L11D03-EN

72 Return to the main menu Edit parameter value Next parameter inside the same group Previous parameter inside the same group MODIFYING PARAMETER VALUE Decrease parameter value Increase parameter value Previous parameter Long Press: Return to the upper menu Next parameter L11D03-EN

73 15.5. PROGRAMMING MODE EXIT To exit the program mode press one of the mode selection keys. If no button is pressed during 2 minutes the program mode will be cancelled automatically. Press any mode button L11D03-EN

74 16. PROGRAM PARAMETER LIST CONTROLLER CONFIGURATION GROUP Parameter Definition Unit Min Max Factory Set LCD Contrast Screen Scroll Timer sec Language Genset Default Display Status Prompt Window Enable Fault Holdoff Timer sec Alarm Relay Timer sec Intermittent Alarm Relay Emergency Backup Operation Exerciser Enable Exercise Period Exercise Off/On Load Description This parameter is used to set LCD contrast. Adjust for the best viewing angle. The screen will scroll between different measurements with this interval. If set to zero, the screen scroll will be disabled. 0: English language selected. 1: Local language selected. This language may depend on the country where the unit is intended to be used. This parameter selects the screen which is displayed during genset on load operation. 0: genset voltages table 1: genset currents and freq. table 2: genset kw and pf table 3: genset kva and kvar table 4: genset average measurements 0: Status prompts disabled 1: Status prompts enabled This parameter defines the delay after the engine runs and before the fault monitoring is enabled. This is the period during which the ALARM relay is active. If the period is set to 0, this will mean that the period is unlimited. 0: continuous 1: intermittent (turns on and off every second) 0: In RUN mode, the load will not be transferred to the genset even if the mains fails. 1: In RUN mode, the load will be transferred to the genset if the mains fails. 0: automatic exerciser disabled 1: automatic exerciser enabled 0: exercise once per week 1: exercise once per month The exact exerciser day and time is adjusted within the EXERCISE SCHEDULE section. 0: Exercise at RUN mode 1: Exercise at TEST mode L11D03-EN

75 16.1. CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition Unit Min Max Factory Set Delayed Simulate Mains Modem / GPS Selection External Modem / GPS Baud Rate bps SMS Enable GPRS Connection Enable Rainbow Scada Refresh Rate Rainbow Scada Address-1 Port Rainbow Scada Address-2 Port sec SMTP Port Description 0: delayed simulate mains disabled 1: delayed simulate mains enabled 0: no modem 1: Internal GSM modem 2: external Datakom modem 3: external generic modem 4: no modem, GPS on RS-232 5: Internal modem, GPS on RS-232 This is the data rate of the RS-232 port for the external modem / GPS. 0: SMS messages disabled 1: SMS messages enabled 0: GPRS disabled 1: GPRS enabled The unit will update the distant monitoring terminal with this rate. This is the port number of the first monitoring terminal address. This is the port number of the second monitoring terminal address. This is the port number used for sending. L11D03-EN

76 16.1. CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition Unit Min Max Factory Set Modbus Address RS-485 Baud Rate bps Oil Pressure Switch Priority Flashing Relay ON Timer min Flashing Relay OFF Timer min Real Time Clock Adjust Hysteresis Voltage V-AC Engine Control Only Alternator Pole Pairs RPM from genset frequency Crank Teeth Count Description This is the modbus controller identity used in Modbus communication. This is the data rate of the RS-485 Modbus port. 0: crank cut is performed through oil pressure switch and oil pressure sender reading 1: crank cut is performed only through oil pressure switch Delayed Simulate Mains Operation: max genset running time after Simulate Mains signal disappears. Dual Genset Systems: flashing relay ON state duration timer. Dual Genset Systems: flashing relay OFF state duration. This parameter trims precisely the real time clock circuit. Values from 0 to 63 speed up the clock with 0.25sec/day steps. Values from 127 to 64 slow down the clock with 0.25sec/day steps. This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions. For example, when the mains are present, the mains voltage low limit will be used as the programmed low limit. When the mains fail, the low limit will be incremented by this value. It is advised to set this value to 8 volts. 0: Genset control 1: Engine control (no alternator) This parameter is used for frequency to rpm conversion. For a 1500/1800 rpm engine select 2. For a 3000/3600 rpm engine select 1. 0: read rpm from the MPU input 1: convert frequency to rpm (using Alternator Pole Pairs) This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel. L11D03-EN

77 16.1. CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition Unit Min Max Factory Set SMS on Mains Change SMS on IP Change on IP Change Fuel Pump Low Limit % Fuel Pump High Limit % Warning Before Start Latch all Warnings Remote Control Enable Annunciator Mode CT Location - Gen Load Gen Reverse CT Direction Description This parameter controls SMS sending when mains voltages status is changed. No warnings generated. 0: no SMS on mains failed or restored 1: SMS sent on mains failed or restored This parameter controls SMS sending when IP address of GPRS connection is changed. No warnings generated. 0: no SMS on IP change 1: SMS sent on IP change This parameter controls sending when IP address of GPRS or ethernet connection is changed. No warnings generated. 0: no on IP change 1: sent on IP change If the fuel level measured from the sender input falls below this level, then the FUEL PUMP function will become active. If the fuel level measured from the sender input goes above this level, then the FUEL PUMP function will become passive. This parameter controls the activation of the ALARM output during Engine Start Delay timer before engine run. 0: no warning before start 1: warning before start 0: warnings are latching/non-latching on parameter control 1: all warnings are latched. Even if the fault source is removed, warnings will persist until manually reset. This parameter controls remote control of the unit through Rainbow, Modbus and Modbus TCP/IP. 0: remote control disabled 1: remote control enabled 0: normal operation 1: the unit becomes an annunciator of the remote unit. Engine/genset control functions are disabled. 0: CTs are at the genset side. Mains currents are not measured. 1: CTs are at load side. Both mains and genset currents are monitored following contactor status. This parameter is useful to invert all CT polarities at the same time. 0: normal CT polarity assumed. 1: reverse CT polarity assumed. L11D03-EN

78 16.1. CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition Unit Min Max Factory Set Unit Functionality AMF LCD Backlight Dimming Delay min Fuel Filling Timer sec SMS Commands Enabled Open with Last Mode Pre-Transfer Delay sec on mains change Enable Auto not Ready Warning Fuel Pulses from MPU input Description 0: AMF functionality. The unit controls both engine and load transfer. The genset starts based on mains status. 1: ATS functionality. The unit controls the load transfer and issues genset start signal based on mains status. 2: REMOTE START functionality. The unit controls engine and alternator. The genset starts with external signal. 3: RESERVED. Not used. If no button is pressed during this period, then the unit will reduce the LCD screen backlight intensity in for economy. After activation of the fuel pump function, if the Fuel Pump High Limit level is not reached, then the fuel pump will stop for safety. If this parameter is set to zero, then the timer is unlimited. 0: SMS commands not accepted 1: SMS commands are accepted but from listed telephone numbers only. 0: The unit powers up in STOP mode 1: The unit powers up in the same operating mode before power down. If this parameter is not zero, the unit will activate the Wait Before Transfer output function during this timer, before initiating a load transfer. This function is designed for elevator systems, in order to bring the cabin to a floor and open doors before transfer. 0: No at mains status changes 1: s sent at mains status change 0: Auto not Ready Warning disabled 1: Auto not Ready Warning enabled 0: MPU input is used for engine speed detection 1: MPU input is used for reading the flowmeter pulses during fuel filling. L11D03-EN

79 16.1. CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition Unit Min Max Factory Set Description Fuel Pulses per Volume This is the number of pulses produced by the flowmeter for the unit volume. This parameter is characteristic of the flowmeter used and should be set according to the flowmeter data. Fuel Counter Unit Lt/gal - - liters This is the unit for the fuel counter SMS on Engine Run/Stop on Engine Run/Stop Fuel Counter Type Dual Genset Equal Aging Enabled CT Secondary Rating Automatic Topology Detection Maintenance Done Warning Enable Stop Status Screens Time Zone min This parameter controls SMS sending when the engine runs or stops. No warnings generated. 0: no SMS on engine run/stop 1: SMS sent on engine run/stop This parameter controls sending when the engine runs or stops. No warnings generated. 0: no on engine run/stop 1: sent on engine run/stop This parameter determines the purpose of fuel pulses 0: Fuel filling pulses, increment fuel counter 1: Fuel consumption pulses, display consumption. 0: Equal aging not enabled 1: Equal aging enabled 0: xxx/5a 1: xxx/1a If this parameter is enabled, when the engine runs, the controller will detect the connection topology automatically and will select alarm levels accordingly. 0: auto detect not enabled 1: auto detect enabled If enabled, the unit will generate a nonvisual warning when maintenance counters are reset. In consequence, SMS and s will be sent, the warning will be visible on the central monitoring system. 0: maintenance warning disabled 1: maintenance warning enabled 0: Enable status screens 1: Disable status screens This parameter adjusts the time zone of the controller, in order to allow internal real time clock to be synchronized to the UTC time. L11D03-EN

80 16.2. ELECTRICAL PARAMETERS GROUP Parameter Definition Unit Min Max Factory Set Current Transformer Primary Voltage Transformer Ratio Amp Nominal Voltage V-AC Nominal Frequency Hz Nominal Voltage-2 V-AC Nominal Frequency-2 Hz Nominal Voltage-3 V-AC Nominal Frequency-3 Hz Mains Voltage Low Limit % V-100 V+100 V-20% Mains Voltage High Limit % V-100 V+100 V+20% Mains Voltage Fail Timer sec Description This is the rated value of current transformers. All transformers must have the same rating. The secondary of the transformer will be 5 Amps. This is the voltage transformer ratio. This value will multiply all voltage and power readings. If transformers are not used, the ratio should be set to 1.0 The nominal value of genset and mains voltages. Voltage limits are defined by reference to this value. The nominal value of genset and mains frequency. Frequency limits are defined by reference to this value. When secondary voltage is selected, this is the nominal value of genset and mains voltages. Voltage limits are defined by reference to this value. When secondary frequency is selected, this is nominal value of genset and mains frequency. Frequency limits are defined by reference to this value. When tertiary voltage is selected, this is the nominal value of genset and mains voltages. Voltage limits are defined by reference to this value. When tertiary frequency is selected, this is nominal value of genset and mains frequency. Frequency limits are defined by reference to this value. If one of the mains phases goes under this limit, it means that the mains are off and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Voltage. If one of the mains phases goes over this limit, it means that the mains are off and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Voltage. If at least one of the mains phase voltages goes outside of the limits during this timer, it means that the mains are off and it starts the transfer to the genset in AUTO mode. L11D03-EN

81 16.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Instant Mains Dropout % Mains Frequency Low Limit Mains Frequency High Limit Mains Frequency Fail Timer Genset Low Voltage Warning Limit Genset Low Voltage Shutdown Limit Genset High Voltage Warning Limit Genset High Voltage Shutdown Limit Genset Voltage Fail Timer % F-100 F+100 F-10% % F-100 F+100 F+10% sec % V-100 V+100 V-15% % V-100 V+100 V-20% % V-100 V+100 V+15% % V-100 V+100 V+20% sec Description If the mains phase voltages are outside limits, but not more than this parameter (with reference to nominal voltage), then the genset will run without releasing the mains contactor. When the genset is ready to take the load, the load will be transferred. If this parameter is set to zero then the mains contactor is immediately released at mains failure. If the mains frequency goes under this limit, it means that the mains are off and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Frequency. If the mains frequency goes over this limit, it means that the mains are off and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Frequency. If the mains frequency goes outside of the limits during this timer, it means that the mains are off and starts the transfer to the genset in AUTO mode. If one of the genset phase voltages goes under this limit when feeding the load, this will generate a GENSET LOW VOLTAGE warning. If one of the genset phase voltages goes under this limit when feeding the load, this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop. If one of the genset phase voltages goes over this limit when feeding the load, this will generate a GENSET HIGH VOLTAGE warning. If one of the genset phase voltages goes over this limit when feeding the load, this will generate a GENSET HIGH VOLTAGE shutdown alarm and the engine will stop. If at least one of the genset phase voltages goes outside of the limits during this timer, a genset voltage fault will occur. L11D03-EN

82 16.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Genset Low Frequency Warning Limit Genset Low Frequency Shutdown Limit Genset High Frequency Warning Limit Genset High Frequency Shutdown Limit Genset Frequency Fail Timer Low Battery Voltage Warning Limit Low Battery Voltage Shutdown Limit High Battery Voltage Warning Limit High Battery Voltage Shutdown Limit Battery Voltage Fail Timer Genset Voltage Unbalance Limit Genset Voltage Unbalance Action % F-100 F+100 V-15% % F-100 F+100 F-20% % F-100 F+100 F+15% % F-100 F+100 F+20% sec V-DC V-DC V-DC V-DC sec % Description If the genset frequency goes under this limit when feeding the load, this will generate a GENSET LOW FREQUENCY warning. If the genset frequency goes under this limit when feeding the load, this will generate a GENSET LOW FREQUENCY shutdown alarm and the engine will stop. If the genset frequency goes over this limit when feeding the load, this will generate a GENSET HIGH FREQUENCY warning. If the genset frequency goes over this limit when feeding the load, this will generate a GENSET HIGH FREQUENCY shutdown alarm and the engine will stop. If the genset frequency goes outside of the limits during this timer, a genset frequency fault will occur. If the battery voltage falls below this limit, this will generate a LOW BATTERY warning. If the battery voltage falls below this limit, this will generate a LOW BATTERY shutdown alarm and the engine will stop. f the battery voltage goes over this limit, this will generate a HIGH BATTERY warning. If the battery voltage goes over this limit, this will generate a HIGH BATTERY shutdown alarm and the engine will stop. If the battery voltage goes outside of the limits during this timer, a battery voltage fault will occur. If any genset phase voltage differs from the average more than this limit, it will generate a Voltage Unbalance fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0.0 then voltage unbalance is not monitored 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning L11D03-EN

83 16.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Genset Current Unbalance Limit Genset Current Unbalance Action Genset Reverse Power Warning Limit Genset Reverse Power Loaddump Limit Genset Reverse Power Fail Timer % kw kw sec Genset Overcurrent Limit Amp Genset Overcurrent Limit-2 Genset Overcurrent Limit-3 Genset Overcurrent Action Overcurrent Time Multiplier Amp Amp Description If any genset phase current differs from the average more than this limit, it will generate a Current Unbalance fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0.0 then voltage unbalance is not monitored 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning If the genset power is negative and goes above this limit then a REVERSE POWER warning will be generated. If this parameter is set to 0 then reverse power fault is not monitored. If the genset power is negative and goes above this limit then a REVERSE POWER loaddump will be generated. If the genset power is negative and over limits during this timer, a reverse power fault will occur. If one of the genset phase currents goes over this limit when feeding the load, this will generate a genset overcurrent fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0 then overcurrent fault is not monitored. When secondary voltage is selected, if one of the genset phase currents goes over this limit when feeding the load, this will generate a genset overcurrent fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0 then overcurrent fault is not monitored. When tertiary voltage is selected, if one of the genset phase currents goes over this limit when feeding the load, this will generate a genset overcurrent fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0 then overcurrent fault is not monitored. 0: shutdown alarm 1: loaddump alarm This parameter defines the reaction speed of the overcurrent detector. A higher number means higher sensitivity. Detailed explanation is given at chapter: Overcurrent Protection L11D03-EN

84 16.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Genset Overload Limit kw Genset Overload Fail Timer sec Load Shedding Low Limit kw Load Shedding High Limit kw Load Add Delay sec Load Subtract-Add Delay min Mains Waiting Timer sec Mains Connection Topology Description If the total genset active power goes over this limit when feeding the load, this will generate a genset overload loaddump alarm. If this parameter is set to 0 then overload fault is not monitored. If the genset active power is over the limit during this timer, an overload fault will occur. If the genset power goes below this limit then the load shedding relay will be deactivated. Review chapter Load Shedding for more details. If the genset power goes above this limit then the load shedding relay will be activated. Review chapter Load Shedding for more details. This is the minimum delay between 2 load_add pulses. Review chapter Load Shedding for more details. This is the minimum delay required for a load_add pulse after a load_substract pulse. Review chapter Load Shedding for more details. This is the time between the mains voltages and frequency entered within the limits and the generator contactor is deactivated. This is the connection topology of mains voltages and CTs. Detailed explanations are given in the chapter: TOPOLOGIES. 0: 2 phase, 3 wire L1-L2 1: 2 phase, 3 wire L1-L3 2: 3 phase, 3 wire 3: 3 phase, 3 wire, 2CTs L1-L2 4: 3 phase, 3 wire, 2CTs L1-L3 5: 3 phase, 4 wire star 6: 3 phase, 4 wire delta 7: single phase, 2 wire This is the connection topology of genset voltages and CTs. Detailed explanations are given in the chapter: TOPOLOGIES. Genset Connection Topology : 2 phase, 3 wire L1-L2 1: 2 phase, 3 wire L1-L3 2: 3 phase, 3 wire 3: 3 phase, 3 wire, 2CTs L1-L2 4: 3 phase, 3 wire, 2CTs L1-L3 5: 3 phase, 4 wire star 6: 3 phase, 4 wire delta 7: single phase, 2 wire L11D03-EN

85 16.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Mains Contactor Timer sec Mains MCB Close Pulse sec Mains MCB Open Pulse sec Mains MCB Under Voltage Coil Timer sec MCB Alarm Level Mains MCB Fail Timer sec Mains Phase Order Check Enable Genset Contactor Timer sec Genset MCB Close Pulse sec Genset MCB Open Pulse sec Genset MCB Under Voltage Coil Timer sec Description This is the period after the generator contactor has been deactivated and before the mains contactor has been activated. After the mains MCB_undervoltage coil is energized and mains MCB_undervoltage coil timer is elapsed, the mains MCB_close relay will be activated during this period. Review chapter Motorized Circuit Breaker Control for more details. The mains MCB_open relay will be activated during this period. Review chapter Motorized Circuit Breaker Control for more details. The mains MCB_undervoltage coil is energized during this period before the mains MCB_close relay is activated. Review chapter Motorized Circuit Breaker Control for more details. 0: shutdown alarm 1: loaddump alarm If a mains MCB feedback input is defined and if the mains MCB fails to change position before the expiration of this timer, then a fault condition occurs. 0: mains phase order checking disabled 1: if mains phase order is faulty, then a warning is given and mains contactor deenergized. This is the period after the mains contactor has been deactivated and before the genset contactor has been activated. After the genset MCB_undervoltage coil is energized and genset MCB_undervoltage coil timer is elapsed, the genset MCB_close relay will be activated during this period. Review chapter Motorized Circuit Breaker Control for more details. The genset MCB_open relay will be activated during this period. Review chapter Motorized Circuit Breaker Control for more details. The genset MCB_undervoltage coil is energized during this period before the genset MCB_close relay is activated. Review chapter Motorized Circuit Breaker Control for more details. L11D03-EN

86 16.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set GCB Alarm Level Genset MCB Fail Timer sec Genset Phase Order Check Enable Busbar Fail Timer sec Busbar Ready Timer sec Multi Load Subtract Power Level Multi Load Add Power Level Multi Load Subtract Start Delay Multi Load Subtract Wait Delay Multi Load Add Start Delay Multi Load Add Wait Delay kw kw sec sec sec sec Description 0: shutdown alarm 1: loaddump alarm If a genset MCB feedback input is defined and if the genset MCB fails to change position before the expiration of this timer, then a fault condition occurs. 0: genset phase order checking disabled 1: if genset phase order is faulty, then a genset phase order fail loaddump alarm is given. When a genset closes to the Busbar, if the mater genset controller does detect the Busbar voltage at the expiration of this period, a BUSBAR FAIL fault condition will occur. This is the delay after all generators close to the busbar and before the master genset controller acknowledges Busbar ready signal. When the genset active power goes over this limit, the controller will start subtracting load as described in chapter Five Step Load Management. When the genset active power goes below this limit, the controller will start adding load as described in chapter Five Step Load Management. If the load stays over the Multi Load Subtract Power Level parameter during this timer, then 1 step of load is subtracted. This is the minimum period between two load subtract operations. If the load stays below the Multi Load Add Power Level parameter during this timer, then 1 step of load is added. This is the minimum period between two load add operations. L11D03-EN

87 16.3. ENGINE PARAMETERS GROUP Parameter Definition Unit Min Max Factory Set Nominal RPM rpm Nominal RPM-2 rpm Nominal RPM-3 rpm Low RPM Warning Limit % R-100 R+100 R-10% Low RPM Shutdown Limit % R-100 R+100 R-15% High RPM Warning Limit % R-100 R+100 R+10% High RPM Shutdown Limit % R-100 R+100 R+15% RPM Fail Timer sec Overspeed Overshoot Limit % HRSL- 100 HRSL +100 HRSL +10% Loss of Signal Check Loss of Speed Signal Action Loss of Speed Signal Timer Low Charge Voltage Warning Limit Low Charge Voltage Shutdown Limit sec V-DC V-DC Description The nominal value of engine rpm. Lowhigh rpm limits are defined by reference to this value. When secondary frequency is selected, this is the nominal value of engine rpm. Low-high rpm limits are defined by reference to this value. When tertiary frequency is selected, this is the nominal value of engine rpm. Low-high rpm limits are defined by reference to this value. If the engine rpm goes under this limit when feeding the load, this will generate a GENSET LOW RPM warning. If the engine rpm goes under this limit when feeding the load, this will generate a GENSET LOW RPM shutdown alarm and the engine will stop. If the engine rpm goes over this limit when feeding the load, this will generate a GENSET HIGH RPM warning. If the engine rpm goes over this limit when feeding the load, this will generate a GENSET HIGH RPM shutdown alarm and the engine will stop. If the engine rpm goes outside of the limits during this timer, an engine speed fault will occur. If the engine rpm goes over the High RPM Shutdown Limit by this quantity, this will generate immediately a GENSET HIGH RPM shutdown alarm and the engine will stop. 0: speed signal existence not checked 1: If the speed signal is lost, it will generate a Speed Signal Lost fault condition. The action taken upon fault condition is programmable. 0: shutdown alarm 1: loaddump alarm 2: warning If the speed signal is lost during this timer, a Speed Signal Lost fault will occur. If the charge alternator voltage goes under this limit, a charge alternator voltage warning will occur. If the charge alternator voltage goes under this limit, a charge alternator voltage shutdown will occur and the engine will stop. L11D03-EN

88 16.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Charge Voltage Fail Timer Engine Heating Temperature sec C Engine Start Delay min Preheat Timer sec Crank Timer sec Wait Between Starts sec Engine Heating Timer sec Engine Heating Method Cooldown Timer sec Stop Solenoid Timer sec Number of Starts Number of Starts Choke Timer sec Description If the charge alternator voltage goes under limits during this timer, a charge alternator voltage fault will occur. If it is requested that the engine runs without load until reaching a certain temperature, this parameter defines the temperature. This is the time between the mains fails and the fuel solenoid turns on before starting the genset. It prevents unwanted genset operation in battery backed-up loads. This is the time after the fuel solenoid is energized and before the genset is started. During this period the PREHEAT relay output is energized (if assigned by Relay Definitions) This is the maximum start period. Starting will be automatically cancelled if the genset fires before the timer. This is the waiting period between two start attempts. This is the period used for engine heating before load transfer. The genset will not take the load before engine heating is completed. 0: engine is heated during Engine Heating Timer. 1: engine is heated until the coolant temperature reaches the Engine Heating Temperature and at least during the Engine Heating Timer. This is the period that the generator runs for cooling purpose after the load is transferred to mains. This is the maximum time duration for the engine to stop. During this period the STOP relay output is energized (if assigned by Relay Definitions). If the genset has not stopped after this period, a FAIL TO STOP warning occurs. This is the control delay of CHOKE output. The choke output is activated together with the crank output. It is released after this delay or when engine runs (whichever occurs first). L11D03-EN

89 16.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Idle Speed (Run) Timer sec Idle Speed (Stop) Timer sec Idle Holdoff Timer sec Gas Solenoid Delay sec Crank Cut Voltage V-AC Crank Cut Frequency Hz Crank Cut RPM rpm Crank Cut Charge Voltage Crank Cut with Oil Pressure Crank Cut with Oil Pressure Delay V-DC sec Charge Input Connected Fuel Tank Capacity Lt Fuel Consumption per Hour % Description When the engine runs, the Idle output relay function will be active during this timer. While the IDLE output is active, low voltage, low frequency and low rpm checks are disabled. Before the engine stops, the Idle output relay function will be active during this timer. While the IDLE output is active, low voltage, low frequency and low rpm checks are disabled. While the IDLE period is over, low voltage, low frequency and low speed checks are enabled after the expiration of this timer. The gas solenoid of the gas engine (if assigned by Relay Definitions) will be opened after this delay during cranking. The crank relay output is deenergized when the genset phase L1 voltage reaches this limit. The crank relay output is deenergized when the genset frequency reaches this limit. The crank relay output is deenergized when the engine rpm reaches this limit. The crank relay output is deenergized when the charge alternator voltage reaches this limit. 0: no crank cut with oil pressure 1: cranking is cut when oil pressure switch is open or the oil pressure measured is above shutdown limit. If crank cutting with oil pressure is enabled, cranking is cut after this delay when oil pressure switch is open or the oil pressure measured is above shutdown limit. 0: Crank cutting with charge input disabled 1: Crank cutting with charge input enabled The full capacity of the fuel tank. If this parameter is zero, the fuel quantity in the tank is not displayed. This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages. If this parameter is set to 0, then no Fuel Theft and Fuelling sms messages will be sent. If SMS is required, set this parameter to a value above the hourly fuel consumption of the genset. L11D03-EN

90 16.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Coolant Cooler On C Coolant Cooler Off C Coolant Heater On C Coolant Heater Off C Fan Overrun Timer sec Canopy Fan Turn-On C Canopy Fan Turn-Off C Ambient Fan Turn-On C Ambient Fan Turn-Off C Service-1 Engine Hours hours Service-1 Period month Service-1 Alarm Level Description If the coolant temp is above this limit then the cooler relay function will become active. If the coolant temp is below this limit then the cooler relay function will become inactive. If the coolant temp is below this limit then the heater relay function will become active. If the coolant temp is above this limit then the heater relay function will become inactive. The cooler relay will stay active during this timer after the coolant temp is below Coolant Cooler Off limit. If the canopy temp is above this limit then the canopy fan relay function will become active. If the canopy temp is below this limit then the canopy fan relay function will become inactive. If the ambient temp is above this limit then the ambient fan relay function will become active. If the ambient temp is below this limit then the ambient fan relay function will become inactive. The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to 0 no SERVICE REQUEST will be generated depending on service-1 engine hours. The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to 0 no SERVICE REQUEST will be indicated depending on Service-1 Period. 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning L11D03-EN

91 16.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set Service-2 Engine Hours hours Service-2 Period month Service-2 Alarm Level Service-3 Engine Hours hours Service-3 Period month Service-3 Alarm Level J1939 Enable J1939 Engine Brand Description The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to 0 no SERVICE REQUEST will be generated depending on service-2 engine hours. The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to 0 no SERVICE REQUEST will be indicated depending on Service-2 Period. 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to 0 no SERVICE REQUEST will be generated depending on service-3 engine hours. The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to 0 no SERVICE REQUEST will be indicated depending on Service-3 Period. 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning 0: The J1939 port is inoperative. 1: The analog measurements (oil, temp, and rpm) are picked up from the ECU. If the ECU communication is lost, then the engine will be stopped. 0: GENERIC 1: CUMMINS 2: DETROIT DIESEL 3: DEUTZ 4: JOHN DEERE 5: PERKINS 6: VOLVO 7: CATERPILLAR 8: SCANIA 9: IVECO 10: MTU-MDEC 11: BOSCH Other values: Reserved. Do not use. L11D03-EN

92 16.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Fact.Set Description J1939 ECU Type GENERIC ENGINE BRAND 0: Generic CUMMINS ENGINE 0: CM850 1: CM570 DETROIT DIESEL ENGINE 0: Generic DEUTZ ENGINE 0: Generic 1: EMR2 2: EMR3 JOHN DEERE ENGINE 0: Generic PERKINS ENGINE 0: Generic 1: ADEM3 2: ADEM 1.3 VOLVO ENGINE 0: Generic 1: without CIU unit 2: EDC4 CATERPILLAR ENGINE 0: Generic SCANIA ENGINE 0: Generic 1: Single Speed 2: All Speed IVECO ENGINE 0: Generic 1: Vector 2: NEF/CURSOR MTU-MDEC ENGINE 0: MDEC 302 1: MDEC 201 2: MDEC 303 3: MDEC 304 4: MDEC 506 BOSCH INJECTION SYSTEM 0: Generic 1: EDC 731 2: EDC 9.3 L11D03-EN

93 16.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Min Max Factory Set J1939 Speed Adjust % High Air Inlet Temperature Warning Limit High Air Inlet Temperature Alarm Limit High Air Inlet Temperature Alarm Action Low Coolant Level Warning Limit Low Coolant Level Alarm Limit Low Coolant Level Alarm Action Battery Charge Run Voltage Battery Charge Run Timer C C % % V-DC min Oil Pump Stop Pressure bars Service Reset Service Reset Service Reset Description This parameter adjusts the speed of an ECU controlled engine by +/- 8%. If the air inlet temperature measured through ECU is over this limit, then a high air inlet temperature warning will occur. If the air inlet temperature measured through ECU is over this limit, then a high air inlet temperature shutdown/loaddump alarm will occur. 0: shutdown alarm 1: loaddump alarm If the coolant level measured through ECU is below this limit, then a low coolant level warning will occur. If the coolant level measured through ECU is below this limit, then a low coolant level shutdown/loaddump alarm will occur. 0: shutdown alarm 1: loaddump alarm If the battery voltage goes below this limit the engine will be automatically started in order to charge the battery using the charge alternator. If the battery voltage goes below the Battery Charge Run Voltage limit, the engine will be automatically run during this period in order to charge the battery using the charge alternator. The oil pump is activated prior to the crank cycle and stopped when this pressure level is reached. If this value is set to zero, then the oil pump is not activated. 0: no action 1: reset service-1 counters 0: no action 1: reset service-3 counters 0: no action 1: reset service-3 counters L11D03-EN

94 16.4. ADJUST DATE AND TIME These parameters allow adjusting the battery backup real time clock of the module. Once set, the clock will continue to run even if DC power is removed from the unit. Parameter Definition Unit Min Max Description Date Current day of the month. Month Current month. Year Last two digits of the current year. Hours Current hour of the day. Minutes Current minute of the hour. Seconds Current second of the minute WEEKLY OPERATION SCHEDULE In AUTO mode, it is possible to define the periods where automatic operation is desired. It may be required that the genset does not start at night or weekends. Weekly schedule programs allow an hourly setting of automatic operation of the unit during one week. There are 7days x 24hours =144 parameters. Each hour of the week can be independently defined as AUTO or OFF period. If automatic operation is disabled by the weekly exerciser, the AUTO led will flash. L11D03-EN

95 16.6. EXERCISER SCHEDULE The unit provides 7 independent automatic exerciser programs. Automatic exercise may be done in weekly or monthly basis. If monthly exercise is selected, the week, day and hour is adjustable for each exercise item. If weekly exercise is selected, the day and hour is adjustable for each exercise item. Exercise can be done with or without load. Thus the genset can be instructed to run automatically in given days and times of a week and take the load. L11D03-EN

96 16.7. SENDER CONFIGURATION The unit has 4 analog sender inputs. Only parameters of one sender are explained below. Other senders have identical parameter set. Each sender has 16 step programmable curves. The sender name and reading unit is freely programmable, thus the sender can be adapted to any type through programming. Each sender has below programmable parameters: Parameter Definition Unit Min Max Factory Set Sender Type Alarm Level Alarm Handling Sender Open Alarm Low Alarm Check Enable Low Warning Check Enable High Alarm Check Enable Description Selects between predefined sender functions. If this parameter is set to then the sender name string can be freely entered. 0: shutdown alarm 1: loaddump alarm 0: always 1: on engine running 2: after hold-off timer 3: reserved If sender resistor is above 5000 ohms, a fault case is generated. This parameter defines the action taken upon fault case. 0: no alarm 1: shutdown alarm 2: loaddump alarm 3: warning The low alarm may be selected as shutdown or loaddump with alarm level parameter. 0: low value alarm disabled 1: low value alarm enabled 0: low value warning disabled 1: low value warning enabled The high alarm may be selected as shutdown or loaddump with alarm level parameter. 0: high value alarm disabled 1: high value alarm enabled High Warning Check 0: high value warning disabled Enable 1: high value warning enabled If enabled, defines the low alarm limit. Low Alarm Level x The low alarm may be selected as shutdown or loaddump with alarm level parameter. Low Warning Level x If defined, defines the low warning. High Alarm Level x If enabled, defines the high alarm limit. The high alarm may be selected as shutdown or loaddump with alarm level parameter. High Warning Level x If defined, defines the high warning. L11D03-EN

97 Parameter Definition Unit Min Max Factory Description Set Sender Curve-1 ohm ohms Point-1 ohm value Sender Curve-1 value x Point-1 reading Sender Curve-2 ohm ohms Point-2 ohm value Sender Curve-2 value x Point-2 reading Sender Curve-3 ohm ohms Point-3 ohm value Sender Curve-3 value x Point-3 reading Sender Curve-4 ohm ohms Point-4 ohm value Sender Curve-4 value x Point-4 reading Sender Curve-5 ohm ohms Point-5 ohm value Sender Curve-5 value x Point-5 reading Sender Curve-6 ohm ohms Point-6 ohm value Sender Curve-6 value x Point-6 reading Sender Curve-7 ohm ohms Point-7 ohm value Sender Curve-7 value x Point-7 reading Sender Curve-8 ohm ohms Point-8 ohm value Sender Curve-8 value x Point-8 reading Sender Curve-9 ohm ohms Point-9 ohm value Sender Curve-9 value x Point-9 reading Sender Curve-10 ohm ohms Point-10 ohm value Sender Curve-10 value x Point-10 reading Sender Curve-11 ohm ohms Point-11 ohm value Sender Curve-11 value x Point-11 reading Sender Curve-12 ohm ohms Point-12 ohm value Sender Curve-12 value x Point-12 reading Sender Curve-13 ohm ohms Point-13 ohm value Sender Curve-13 value x Point-13 reading Sender Curve-14 ohm ohms Point-14 ohm value Sender Curve-14 value x Point-14 reading Sender Curve-15 ohm ohms Point-15 ohm value Sender Curve-15 value x Point-15 reading Sender Curve-16 ohm ohms Point-16 ohm value Sender Curve-16 value x Point-16 reading Sender Name If the sender type parameter is set to zero (not used), this string is used as sender name while displaying the sender reading. Sender Low Fault String If the sender type parameter is set to zero (not used), this string is used as sender low value fault in the alarm display. Sender High Fault String If the sender type parameter is set to zero (not used), this string is used as sender high value fault in the alarm display. L11D03-EN

98 16.8. DIGITAL INPUT CONFIGURATION The unit has 8 digital inputs. By using external input extension modules, up to 40 inputs in total are available. Only parameters of one input are explained below. Other inputs have identical parameter set. The input name is freely programmable, thus the input can be adapted to any functionality through programming. The input name entry is made through RainbowPlus program only. Each sender has below programmable parameters: Parameter Definition Unit Min Max Factory Set Input Function Action Sampling Latching Contact type Switching Response delay Description Selects between predefined input functions. Selected input name is displayed in the line below. If this parameter is set to 0 then the input name string can be freely entered. 0: shutdown alarm 1: loaddump alarm 2: warning 3: no fault condition from this input. 0: always 1: on engine running 2: after hold-off timer 3: reserved 0: non-latching. The fault disappears when cause is removed. 1: latching. The fault persists even if the cause is removed. Requires manual reset. 0: Normally open 1: Normally closed 0: Battery negative 1: Battery positive 0: No delay 1: Delayed (1sec) 2: Delayed (10sec) 3: Delayed (1800sec) L11D03-EN

99 INPUT FUNCTION LIST No Description 1 User Defined Function 2 Low Oil Press. Switch 3 High Temp. Switch 4 Coolant Level Switch 5 Rectifier Fail Switch 6 Emergency Stop 7 Alternator High Temp 8 Excitation Loss Sw. 9 Low Fuel Switch 10 Earthquake Detector 11 Gen Cont Auxiliary 12 Mains Cont Auxiliary 13 Force AUTO Mode 14 Force OFF Mode 15 Force TEST Mode 16 Over Load Switch 17 Manual Fuel Fill! 18 Priority 19 Remote Start 20 Disable Auto Start 21 Force to Start 22 Fault Reset 23 Alarm Mute 24 Panel Lock 25 Fuel Pump Switch 26 Secondary Volt&Freq 27 Disable Protections 28 Auto Restore Inhibit 29 GensetLoadingInhibit 30 Air Flap Fault 31 Canopy Door Open 32 Station Door Open 33 Station Over-Heat Sw. 34 Weather Cloudy 35 Weather Rainy 36 Lightning 37 Cooler Fan Fault 38 Heater Fan Fault 39 Canopy Fan Fault 40 Station Fan Fault No Description 41 Over Resonance 42 Short-Circuit Alarm 43 Reset Service 1 Alm 44 Reset Service 2 Alm 45 Reset Service 3 Alm 46 Heavy Duty 47 Synchro Genset Run 48 Synch Genset on Load 49 Program Lock 50 Fire Circuit Press.Sw. 51 Lamp Test 52 Combat Mode 53 Disable Peak Lopping 54 Disable Power Export 55 Tertiary Volt Freq. 56 Follower Power Export 57 Remote priority+1 58 Remote priority+2 59 Remote priority+4 60 Remote priority+8 61 Mains restore inhibit No Description Input not in Use L11D03-EN

100 16.9. OUTPUT CONFIGURATION The parameters below define the functions of relay outputs. The unit has 8 relay outputs. All relays have programmable functions, selected from a list. Relays may be extended up to 40 using Relay Extension Modules.. Other relays are in the optional Extension Modules. Parameter Definition Factory Terminal Description set number Relay Factory set as Crank Relay output Relay Factory set as Fuel Relay output Relay Factory set as Horn Relay output Relay Factory set as Preheat Relay output Relay Factory set as Stop Relay output Relay Factory set as Idle Speed Relay output Relay Factory set as Mains Contactor Relay output Relay Factory set as Genset Contactor Relay output Relay Relay extension module 1 Relay Relay extension module 1 Relay Relay extension module 1 Relay Relay extension module 1 Relay Relay extension module 1 Relay Relay extension module 1 Relay Relay extension module 1 Relay Relay extension module 1 Relay Relay extension module 2 Relay Relay extension module 2 Relay Relay extension module 2 Relay Relay extension module - 2 Relay Relay extension module - 2 Relay Relay extension module - 2 Relay Relay extension module - 2 Relay Relay extension module - 2 Relay Relay extension module - 3 Relay Relay extension module - 3 Relay Relay extension module - 3 Relay Relay extension module - 3 Relay Relay extension module - 3 Relay Relay extension module - 3 Relay Relay extension module - 3 Relay Relay extension module - 3 Relay Relay extension module - 4 Relay Relay extension module - 4 Relay Relay extension module - 4 Relay Relay extension module - 4 Relay Relay extension module - 4 Relay Relay extension module - 4 Relay Relay extension module - 4 Relay Relay extension module - 4 Below is a short list for reference purposes. Please use the RainbowPlus program for complete selection list. L11D03-EN

101 OUTPUT FUNCTION LIST No Description 1 Fuel 2 Horn 3 Crank 4 Stop Solenoid 5 Genset Contactor 6 Mains Contactor 7 Idle Speed 8 Preheat 9 Alternate Crank 10 Fuel Main Winding 11 Genset Close Pulse 12 Genset Open Pulse 13 Genset UV Coil 14 Mains Close Pulse 15 Mains Open Pulse 16 Mains UV Coil 17 Flashing Relay 18 Gas Solenoid 19 Fuel Pump Control 20 Choke 21 Block Heater 22 Coolant Cooler 23 Coolant Heater 24 Fan Control 25 Air Flap Control 26 Canopy Fan Control 27 Ambient Fan Control 28 Remote Start Output 29 Genset Ready 30 Bus Bar Contactor 31 Bus Bar Close Pulse 32 Bus Bar Open Pulse 33 Bus Bar UV Coil 34 Load Shedding 35 Load Add 36 Load Substract 37 Service 1 Request 38 Service 2 Request 39 Service 3 Request 40 Mains Ph.Order Fail 41 Genset Ph.Order Fail 42 Auto Ready 43 Weekly Schedule On 44 Exerciser On 45 Mains Fail No Description 46 Pgm Mode Active 47 Engine Running 48 Genset Voltage Ok 49 Alarm Check Enable 50 Oil Pressure Ok! 51 Shutdown Alarm 52 Loaddump Alarm 53 Warning Alarm 54 Shutdown or Loaddump 55 Shut. or LDD or Warn 56 Test Mode 57 Auto Mode 58 Manual Mode 59 Off Mode 60 Not In Auto 61 Genset At Rest 62 Waiting Before Fuel 63 Preheating 64 Waiting Oil Flash Off 65 Engine Heating 66 Synchronizing 67 Cooling Down 68 Stopping 69 Protections Disabled 70 Remote Start Input 71 Disable Auto Start 72 Force to Start 73 Auto Restore Inhibited 74 Gen.Loading Inhibited 75 Inp.Expansion1Mounted 76 Inp.Expansion2Mounted 77 Out.Expansion1Mounted 78 Out.Expansion2Mounted 79 Master Unit 80 Multi Gen. Remote Start 81 Remote Control Out 1 82 Remote Control Out 2 83 Remote Control Out 3 84 Remote Control Out 4 85 Remote Control Out 5 86 Remote Control Out 6 87 Remote Control Out 7 88 Remote Control Out 8 89 Remote Control Out 9 90 Remote Control Out 10 No Description 91 Remote Control Out Remote Control Out Remote Control Out Remote Control Out Remote Control Out Remote Control Out Multi Load Add Out 1 98 Multi Load Subst. Out 1 99 Multi Load Add Out Multi Load Subst. Out Multi Load Add Out Multi Load Subst. Out Multi Load Add Out Multi Load Subst. Out Multi Load Add Out Multi Load Subst. Out Heavy Duty Active 108 ECU Power On 109 Battery Charge Run 110 Fire Circuit PS Active 111 Pre-transfer Delay 112 Secondary Volt Freq. 113 Lamp Test Active 114 Alarm Mute Active 115 Combat mode 116 Peak Lopping Active 117 Power Export Active 118 Master Mains Controller 119 Busbar Ready 120 Droop Mode Active 121 Tertiary Volt Freq 122 Smart Load Management 123 Follower mode active 124 Oil pump output 125 Speed Up pulse output 126 Speed down pulse output 127 Volt up pulse output 128 Volt down pulse output 129 Synch OK output 130 Zero Power Relay output L11D03-EN

102 SITE ID STRING The site identity string is designed to identify the current controller. This is the site Id string sent at the beginning of SMS messages, s and web page headers for the identification of the genset sending the message. Any 20 character long string may be entered ENGINE SERIAL NUMBER The engine serial number string is designed to identify the current controller. Th s string is added to GSM-SMS messages, s, web page headers etc MODEM1-2/SMS TELEPHONE NUMBERS These telephone number buffers accept up to 16 digits, including the wait character (, ) in order to enable dialing through a pabx. If Modem Selection= External PSTN Modem: First 2 numbers are used for modem calls. Other selections: all numbers are used for SMS sending. Enter numbers starting from first character. Do not leave blank characters at the beginning. L11D03-EN

103 GSM MODEM PARAMETERS Parameter Definition APN User Name APN Password APN Name SMS Service Center Number Description The APN (access point name) username may be required by the GSM operator. However some GSM operators may allow access without username. The exact information should be obtained from the GSM operator. Please search the GSM operator s website with APN string. If the APN (access point name) username is required by the GSM operator, most probably the APN password will also be required. However some GSM operators may allow access without password. The exact information should be obtained from the GSM operator. Please search the GSM operator s website with APN string. The APN (access point name) is always required by the GSM operator. The exact information should be obtained from the GSM operator. Please search the GSM operator s website with APN string. The SMS service center number may be required by the GSM operator. However some GSM operators may allow SMS sending without SMS service center number. The exact information should be obtained from the GSM operator. Please search the GSM operator s website with sms service center string. Below GSM modem related parameters are found in the Controller Configuration group. Parameter Definition Unit Min Max Factory Set GSM Sim Card Pin SMS Enable GPRS Connection Enable SMS on Mains Change SMS on IP Change Description If the GSM SIM card uses pin number, enter the pin number here. If incorrect pin number is entered, then the SIM card will not operate. 0: SMS messages disabled 1: SMS messages enabled 0: GPRS disabled 1: GPRS enabled This parameter controls SMS sending when mains voltages status is changed. No warnings generated. 0: no SMS on mains failed or restored 1: SMS sent on mains failed or restored This parameter controls SMS sending when IP address of GPRS connection is changed. No warnings generated. 0: no SMS on IP change 1: SMS sent on IP change L11D03-EN

104 ETHERNET PARAMETERS Parameter Definition Factory Set Description Rainbow Address-1 Rainbow Address-2 Mail Account Name Mail Account Password Mail Server Address Address-1 Address-2 Address-3 wss1.datakom.com.tr d500_a d500_1234 smtp.mail.yahoo.com These parameters accept both internet addresses (like and IPv4 addresses (like ). Information for remote monitoring is sent to these addresses. The port information of these addresses are found in Controller Configuration group. This is the account name appearing in the from tab of the recipient. (ex: datakom-d500@gmail.com) This is the password of above account. This is the Outgoing Mail Server Address of the above account (ex: smtp.gmail.com) These are recipient addresses where the unit is intended to send messages. Up to 3 s can be sent at once. Below ETHERNET related parameters are found in the Controller Configuration group. Parameter Definition Unit Min Max Factory Set Rainbow Refresh Rate sec Rainbow Address-1 Port Rainbow Address-2 Port SMTP Port on IP Change Description The unit will update the distant monitoring terminal with this rate. This is the port number of the first monitoring terminal address. This is the port number of the second monitoring terminal address. This is the port number used for sending. This parameter controls sending when IP address of GPRS or ethernet connection is changed. No warnings generated. 0: no on IP change 1: sent on IP change L11D03-EN

105 17. CRANK CUTTING In order to insure fast and reliable crank cutting, the unit uses various resources for engine running condition detection. Cranking is stopped when at least one of below conditions is met: - Crank timer expired: The crank timer is adjusted through Engine Parameters > Crank Timer. The maximum allowed timer is 15 seconds. - Genset AC voltage over threshold: If the genset phase L1 AC voltage reaches Engine Parameters > Crank Cut Voltage, then cranking is immediately stopped. - Genset frequency over threshold: If the genset phase L1 frequency reaches Engine Parameters > Crank Cut Frequency, then cranking is immediately stopped. - Genset rpm over threshold: If the genset rpm reaches Engine Parameters > Crank Cut RPM, then cranking is immediately stopped. - Charge alternator voltage over threshold Following setting is necessary: Engine Parameters > Charge Input Connected = 1 If the charge alternator voltage reaches Engine Parameters > Crank Cut Charge Voltage, then cranking is immediately stopped. - Oil pressure above threshold Following setting is necessary: Engine Parameters > Crank Cut with Oil Pressure = 1 The crank cutting with oil pressure offers a programmable delay through Engine Parameters > Crank Cut with Oil Pressure Delay. The parameter is factory set to 2 seconds. Both low oil pressure switch and oil pressure sender readings may be used for crank cutting. The oil pressure switch is always used. The sender may be disabled through Controller Configuration > Oil Pressure Switch Priority parameter. If enabled, when oil pressure is detected, cranking is stopped after adjustable timer delay. L11D03-EN

106 18. OVERCURRENT PROTECTION (IDMT) The unit offers a programmable IDMT protection function in order to protect the alternator against excessive currents. The IDMT (Inverse Definite Minimum Time) protection function has such tripping characteristics that the tripping time varies inversely with the value of current. Beyond a certain current limit the tripping time becomes constant (definite) and causes tripping in minimum time. The tripping formula is defined as below: Where: TMS is the IDMT time multiplier setting. This is also the tripping time at 100% overload. I is the current of the most loaded phase I set is the programmed overcurrent limit t is the tripping time in seconds Currents below the overcurrent limit are allowed to flow for unlimited time. Currents above the limit will cause the IDMT protection to trigger with a delay depending on the strength of the overcurrent. Higher the current, faster the protection will trip. When a non-tripping overcurrent condition occurs, the unit will keep trace of it. In case of a consecutive overcurrent, the controller will take into account the residual heat caused by the previous overcurrent and will trip faster than usual. The IDMT multiplier adjusts the sensitivity of the IDMT detector. When the multiplier is low, then tripping will be faster for the same current. The unit provides separate Overcurrent limits for primary, secondary and tertiary volt/speed/amp settings. Switching from primary volt/freq/amps to secondary or tertiary values will also switch the IDMT detector to the secondary/tertiary setting. The action of the tripping may be selected as a Loaddump (stop after cooldown) or shutdown alarm (immediate stop). Screenshot from RainbowPlus configuration program, Generator>Current section L11D03-EN

107 Below is a table showing the tripping delay in function of the percent load level (with TMS=36): 100% unlimited 170% 73s 240% 18s 110% 3600s 180% 56s 250% 16s 120% 900s 190% 44s 260% 14s 130% 400s 200% 36s 270% 12s 140% 225s 210% 30s 280% 11s 150% 144s 220% 25s 290% 10s 160% 100s 230% 21s 300% 9s Below is the tripping delay curve in function of the load level (with TMS=36): L11D03-EN

108 19. MOTORIZED CIRCUIT BREAKER CONTROL The unit offers full control for any brand and model of motorized circuit breakers (MCB). The MCB control is performed through 3 digital output functions, namely Open, Close and Undervoltage coil controls. Only 2 of these outputs are used in a single application. Any digital output can be assigned to MCB control signals through programming menu. The MCB CLOSE sequence is below: Activate UV output, wait for undervoltage coil timer (tuv) Activate CLOSE output, wait for close pulse timer (tcl) Deactivate CLOSE output The MCB OPEN sequence is below: Deactivate UV output Activate OPEN output, wait for open pulse timer (top) Deactivate OPEN output Open Pulse, Close Pulse and Undervoltage Coil timers are adjusted through programming menu. If MCB feedback input is defined and the MCB fails to change position after the expiration of MCB Fail timer, then a fault condition will occur. L11D03-EN

109 MCB modules can be operated by 2 different ways. The unit supports both configurations. Below is the terminology used: M: gear motor PF: ready to close contact XF: close coil MX: open coil MN: undervoltage trip (release) AUX: auxiliary contacts MCB WITH OPEN-CLOSE COILS MCB WITH CLOSE-UV COILS In the diagram at left, relay function assignments should be as below: OUTx: Mains (or Genset) Close Pulse OUTy: Mains (or Genset) Open Pulse In the diagram at right, relay function assignments should be as below: OUTx: Mains (or Genset) Close Pulse OUTy: Mains (or Genset) Undervoltage Coil L11D03-EN

110 20. J1939 CANBUS ENGINE SUPPORT The unit offers a special J1939 port in order to communicate with electronic engines controlled by an ECU (electronic control unit). The J1939 port consists of 2 terminals which are J1939+ and J The connection between the unit and the engine should be made with an appropriate balanced 120 ohms low capacitance coaxial cable. The external conductor should be grounded at one end only. A 120 ohms termination resistor is installed inside the unit. Please do not connect external resistor. The J1939 port is activated by setting the program parameter J1939 Enable to 1. The J1939 Engine Type parameter should be set accordingly. The list of available engines is given at the programming section. Please contact DATAKOM for the most current list of engines. If the J1939 port is enabled then the oil pressure, coolant temperature and the engine rpm information are picked up from the ECU unit. If connected, the MPU unit and related analog senders are discarded. The controller is able to read and display all below parameters, under condition that the engine sends these information. Most engines send only some of them. If the engine does not send a parameter, the unit will simply skip it. Thus only available information are displayed. The complete list of J1939 display parameters is below: PGN / SPN 247 Engine Total Hours of Operation PGN / SPN 250 Engine Total Fuel Used PGN / SPN 110 Engine Coolant Temperature / SPN 174 Engine Fuel Temperature 1 / SPN 175 Engine Oil Temperature 1 PGN / SPN 100 Engine Oil Pressure / SPN 94 Engine Fuel Delivery Pressure / SPN 98 Engine Oil Level / SPN 101 Engine Crankcase Pressure / SPN 109 Engine Coolant Pressure / SPN 111 Engine Coolant Level PGN / SPN 183 Engine Fuel Rate / SPN 184 Engine Instantaneous Fuel Economy / SPN 185 Engine Average Fuel Economy PGN / SPN 108 Barometric Pressure / SPN 171 Ambient Air Temperature / SPN 172 Engine Air Inlet Temperature PGN / SPN 102 Engine Turbocharger Boost Pressure / SPN 105 Engine Intake Manifold 1 Temperature / SPN 106 Engine Air Inlet Pressure / SPN 107 Engine Air Filter 1 Differential Pressure / SPN 173 Engine Exhaust Gas Temperature PGN / SPN 158 PGN / SPN 92 Engine Percent Load At Current Speed / SPN 91 Accelerator Pedal Position 1 PGN / SPN 190 Engine Speed / SPN 513 Actual Engine - Percent Torque / SPN 512 Driver's Demand Engine - Percent Torque The J1939 measurements are also available for Modbus operation. Please check chapter Modbus Communications for more details. When the fuel output is active, if no information is received from the ECU during last 3 seconds, then the unit will give a ECU FAIL alarm and stop the engine. This feature prevents uncontrolled engine operation. The fault conditions of an electronic engine are considered by the unit as warnings and do not cause engine stop. The engine is supposed protected by the ECU which will stop it when necessary. L11D03-EN

111 The electronic engine fault codes are displayed in text within the alarm list table, together with their SPN-FMI codes. The complete list of fault codes is given in the engine manufacturer s user manual. Below is a basic list of fault conditions (x denotes any FMI) SPN FMI DESCRIPTION 56 x Overspeed shutdown 57 x Low oil pressure shutdown 58 x High engine temp. shutdown 71 x Gain adjust potentiometer fault 75 x Generator speed circuit fault 79 x Frequency adjust potentiometer fault 80 x Droop adjust potentiometer fault 81 x Low oil pressure warning 82 x High engine temp. warning 91 x Accelerator pedal circuit fault 94 x Fuel filter restriction Fuel pressure sensor fail 97 x Water in Fuel 99 x Oil filter differential pressure fault 98 x Low oil level, High oil level, Oil level sensor fail 100 x Low oil pressure, Oil pressure sensor fail 101 x Crankcase pressure fault 102 x Intake manifold 1 pressure fault 103 x Turbocharger 1 speed fault 105 x Intake manifold temp high, Intake manifold temp sensor fail 106 x High boost pressure, Turbo outlet pressure sensor fail 107 x Air filter restriction, Air filter sensor fail 108 x Atmospheric pressure sensor fail 109 x Coolant pressure fault 110 x High coolant temperature, Coolant temperature sensor fail 111 x Low coolant level, Coolant level sensor fail 153 x Crankcase ventilation fault 158 x Battery voltage failure 164 x High injector activation pressure, Injector activation pressure sensor fail 168 x Battery 1 voltage fault 172 x High inlet air temperature, High inlet manifold air temperature, Inlet manifold air temperature sensor fail 173 x Exhaust gas temp. fault 174 x High fuel temperature, Fuel temperature sensor fail 175 x High oil temperature, Oil temperature sensor fail 190 x Overspeed, Speed sensor loss of signal, Speed sensor mechanical failure L11D03-EN

112 SPN FMI DESCRIPTION 234 x Incorrect ECM software 612 x Engine magnetic speed sensor fault 620 x ECU internal +5V fail 626 x Preheating relay fault 627 x Injector power supply fault 629 x ECU hardware fail 630 x ECU memory fail 633 x Fuel injector valve fault 636 x Camshaft sensor 637 x Flywheel sensor 639 x ECU memory fail 644 x External speed comm. Input fault 647 x Fan control circuit fault 651 x Injector cylinder #1 fault 652 x Injector cylinder #2 fault 653 x Injector cylinder #3 fault 654 x Injector cylinder #4 fault 655 x Injector cylinder #5 fault 656 x Injector cylinder #6 fault 657 x Injector cylinder #7 fault 657 x Injector cylinder #8 fault 677 x Start motor relay fail 723 x Secondary engine speed sensor fail 1075 x Electric lift pump circulation fault 1079 x ECU internal +5V fail 1111 x Check configuration parameters 1265 x Engine oil burn valve fault 1377 x Multiple unit synch. Switch fault 1378 x Engine oil change interval 1384 x Engine commanded shutdown 2000 x ECU failure 2433 x Exhaust gas temp. right manifold 2434 x Exhaust gas temp. left manifold 2791 x Internal EGR fail L11D03-EN

113 Below is a basic list of FMI codes. Please be aware that these codes may differ slightly depending on the engine brand and model. FMI DESCRIPTION 0 Value too high Valid data, but above the normal working range 1 Value too low Valid data, but below the normal working range 2 Faulty data Intermittent or faulty data or Short circuit to battery voltage, injector high voltage side 3 Electrical fault Abnormally high voltage or short circuit to battery voltage, injector low voltage side 4 Electrical fault Abnormally low voltage or short circuit to battery negative, injector low voltage or high voltage side 5 Electrical fault Abnormally low current or open circuit 6 Electrical fault Abnormally high current or short circuit to battery negative 7 Mechanical fault Faulty response from mechanical system 8 Mechanical or electrical fault Abnormal frequency 9 Communication fault Abnormal updating rate or Open circuit in injector circuit 10 Mechanical or electrical fault Abnormally large variations 11 Unknown fault Unidentified fault 12 Component fault Faulty unit or component 13 Faulty calibration Calibration values outside the limits 14 Unknown fault Special instructions 15 Data valid but above normal operating range - least severe level 16 Data valid but above normal operating range - moderately severe level 17 Data valid but below normal operating range - least severe level 18 Data valid but below normal operating range - moderately severe level 19 Received network data in error 20 not used (reserved) 21 not used (reserved) 22 not used (reserved) 23 not used (reserved) 24 not used (reserved) 25 not used (reserved) 26 not used (reserved) 27 not used (reserved) 28 not used (reserved) 29 not used (reserved) 30 not used (reserved) 31 Condition exist L11D03-EN

114 21. GPS SUPPORT The unit supports external GPS modules from RS-232 port. RS-232 GPS modules are available at Datakom. DATAKOM RS-232 GPS MODULE Related parameters are: Parameter Definition Unit Min Max Factory Set Modem / GPS Selection External Modem / GPS Baud Rate bps Description 0: no modem 1: Internal GSM modem 2: external Datakom modem 3: external generic modem 4: no modem, GPS on RS-232 5: Internal modem, GPS on RS-232 This is the data rate of the RS-232 port for the external modem / GPS. The GPS screen is found under GSM Modem screen group. Number of detected satellites GPS SCREEN L11D03-EN

115 The GPS location determination is based on signals transmitted by GPS satellites circulating in earth s orbit. 24 satellites are available in total, but the number of satellites in sight will depend on the physical location and time. A minimum of 3 satellites are necessary to determine the location. A fourth satellite is used for verification. More satellites will mean more precision. The unit displays the number of effective satellites on its GPS screen. GPS satellites transmit a precision date and time information as well. This information is displayed on the GPS Screen, but not used elsewhere. The location determination quality of the GPS module will depend on the physical location. The GPS should be installed in a location where it is capable of seeing a large portion of open sky. It can also work on reflections from ground or other buildings without seeing the sky, but location precision will affected by this. GPS based location has priority over GSM based location. If both type of locations are available, then GPS location will be used. Geographical location is stored in a non-volatile memory once an hour. Thus if the GPS signal is lost, the unit continues to appear at the same location of the remote monitoring system. However a GPS warning will be generated on loss of signal or communication with the module. It is possible to program the geographical location inside the controller, forcing it to appear at the desired location of the remote monitoring system. The location setting is done through Rainbow Plus only. Location parameters are found under: Communication>Basic tab Latitude Longitude L11D03-EN